Power Control system

ABSTRACT

A power control assembly for use in an integrated power control system has a base with a housing that defines a cavity adapted for receiving a power switch. The control assembly includes a control module configured for generating control signals for controlling the power switch for selectively providing power to a load. A control housing houses the control module and is adapted to be releasably coupled to the base housing and is configured for electrically coupling to control couplers on the base housing for providing the generated control signals to the power switch within the housing cavity upon coupling the control housing to the base housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/607,342, filed on Sep. 3, 2004. This application is also related toU.S. patent application No. ______, (Attorney Docket 7377-000121/US),filed Sep. 2, 2005, entitled INTEGRALLY COUPLED POWER CONTROL SYSTEMHAVING A SOLID STATE RELAY; and PCT patent application No. ______,(Attorney Docket 7377-000121/WO/POA), filed Sep. 2, 2005, entitled POWERCONTROL SYSTEM. The disclosure of the above applications areincorporated herein by reference.

FIELD OF THE INVENTION

The invention relates generally to a control system, and, moreparticularly, to a control system for controlling power to apower-receiving load.

BACKGROUND

A control system for controlling the power provided to a power-receivingload is traditionally produced and deployed on a discrete componentbasis. Discrete components are selected and combined for the particularapplication or receiving load.

FIG. 1 illustrates a typical exemplary power control arrangementcomposed of a variety of discrete components. These can include acontrol system 102 with an associated control sensor 104, an input 106for receiving power from a power source 108, a contactor 110 forreceiving the power from the power source 108, a limit 112 with anassociated limit sensor 114, a fuse 116, a power switch 118 (shown as asolid state relay), and a power load 120 (shown as a heating element).As illustrated, each of the various discrete components is combined andhard-wired to meet the needs of a particular user process controlapplication constituting a power control system 100. As indicated inFIG. 1, for this typical thermal loop power control application, thecombination of discrete components for a single power loop requires 7discrete components 102, 104, 110, 112, 114, 116, and 118, with 16 wires122A-H and 24 wiring connections, two for each of 16 wires 122A-H, andlabeled, for example as 124A and 124B, for the two wires 122A. However,other discrete components can also be included such as a timer, apressure sensing component, a power monitor, etc. (none of which areshown in FIG. 1). The addition of each of these components will oftenrequire 2 wires 122 and possibly 4 connections 124 to terminate bothends of each wire and can require the rewiring of previous wires inorder to reconfigure the wiring between the various components.

FIG. 2 illustrates another example of a typical power controlarrangement 200 for controlling power for a thermal loop application. Asshown, the control 102 can include a user interface 202 and controller204 and have 6 connections 124 to 6 wires 122. A limit contactor 110 canbe positioned between a power supply bus 206 that is coupled to a powersupply 108 (not shown in FIG. 2) and then wired to a semiconductor fuse116 such as a fast blow fuse. The fuse 116 provides a fusible connectionto a power switch 118 that can be any type of power switch, but is oftena semiconductor-based switch such as solid state relay (SSR), a TRIAC,or a silicon controller rectifier (SCR), by way of example. The powerswitch 118 provides power to a power load 120 such as a heater forheating a user application. A process or application sensor 104 sensesthe temperature of the heater 120 in the user application and providesfeedback to the controller 204 for feedback control of the powering ofthe power load 120, such as a heater. Additionally, as discussed above,the limit contactor 110 receives input from a limit component 112 thatincludes a limit sensor 114. The limit sensor 114 is also located inproximity to the heater 120. The limit system comprised of the limitcontactor 110, the limit component 112, and the limit sensor 114,monitors the operation of the heater 120 to protect the heating elementof the heater 120 from destruction, failure or impairment. The limitcomponent 112 receives power from the power bus 206 through a set ofdevice fuses 208. The limit component 112 determines when the limitsensor 114 has detected a heater condition and signals to the limitcontactor 110 over a separate wire, to initiate a limit action in thelimit contactor 110, thereby preventing power from passing to the powerswitch 118 and therefore to the heater 120. As is also indicated in FIG.2, each discrete component within the power control system 200 requiresseparate wiring 122 and numerous connections 124. Additionally, suchwiring 122 and discrete component installations are often confusing toinstallers and wiring mistakes often result. Common mistakes made duringinstallation include incorrect termination of leads to terminalsresulting in circuit shorting or opens, poor compression of terminals toleads resulting in potential high temperatures at terminals, electricalmagnetic interference with other components, or electromagneticemissions.

As shown in FIG. 3, other common discrete components also includecurrent transformers 302 or sensors or other measurement devices formeasuring one or more characteristics of a power control userapplication. As shown in FIGS. 3A and 3B, one or more currenttransformers 302 can be positioned in the power supply line 304 from thepower switch 118 to the heater power load 120 to sense current suppliedto the heating element. Each current transformer 302 measures a current306 in the power supply line 304 which is provided to a currenttransformer controller (not shown) which is yet another discretecomponent that requires installation, wiring and connections forinstallation into the user application. In some applications, thiswiring requires the breaking of the power line 304 to introduce thecurrent transformer 302 resulting in another opportunity for wiringmistakes.

Similarly, FIG. 4 illustrates another discrete component control system400, having a control switch 118, such as a relay, is electricallylocated between the power load 120 and the contactor 110. The controlrelay 118 receives a control signal 402 from the controller 102 over aseparately wired control lead 404. The control relay 118 operates inresponse to a control signal 402 from the controller 102 to providepower to the contactor 110 and therefore to the power load 120. Again,additional discrete components and specialized wiring are typicallyrequired for another user application.

Generally, typical power control installations require specializedselection of the discrete components, customized mounting and wiring foreach component and feature, and multiple connections. Additionally, anychanges, additions, modifications, and replacements requiredisconnection and reconnection of various wire leads, yet againincreasing the opportunity for wiring mistakes.

As such, existing power control implementations and installations areoften complex and costly to install. Such complexity and costs limittheir application or limit the functionality included in a particularuser application. For example, a limit control for over-voltage or apower monitoring component are not included in many applications whennot required by a regulation due to the required added complexity and/orinstalled cost.

SUMMARY OF THE INVENTION

The present invention generally relates to a power control system thatincludes an integrated operational design. The following presents asummary of the power control system, according to some embodiments ofthe invention, in order to provide a basic understanding of one or moreaspects of the invention. This summary is not an extensive overview, andis neither intended to identify key or critical elements of theinvention, nor to delineate the scope thereof. Rather, the primarypurpose of the summary is to present some aspects of the invention in asimplified form as a prelude to the more detailed description presentedlater.

In one aspect of the invention, a power control system includes anintegration coupling mechanism for mechanical and electrical coupling ofa plurality of power control system components and a communication linkconfigured for providing a communication among a plurality of powercontrol system components utilizing the coupling mechanism. A powerswitch component is adapted for coupling by the unit integrationcoupling mechanism and selectively providing electrical energy to a loadthe power switch component including a power supply interface forreceiving power from a power supply, a power load interface forproviding, at least a portion, of the received supply power to the powerload, and a power switch communication interface configured tocommunicate over the communication link. The power switch componentadapted to the coupling mechanism for mechanical, electrical andcommunication coupling. A power controller component is configured forcontrolling the power switch component and includes a controllercommunication interface for communicating over the communication link tothe power switch component.

In another aspect of the invention, a power control system has aplurality of components and includes a system control component forgenerating a switch control signal and a limit control component forreceiving a sensed limit operating characteristic and generating a limitcontrol signal as a function of the sensed limit operatingcharacteristic. A communication link is configured for providing acommunication between two of the plurality of power control systemcomponents. A power control unit includes a plurality of power controlcomponents and a unit integration coupling mechanism for mechanical andelectrical coupling of the components of the power control unit. Thepower control unit has a power supply interface for receiving power froma power supply, a power load interface for providing, at least a portionof, the received supply power to a power load, and a power switchcomponent for selectively providing electrical energy to a loadresponsive to the switch control signal and adapted to the couplingmechanism. The power switch component includes a power switchcommunication interface configured to communicate with the communicationlink and a limit component for controlling the delivery of the supplypower to the power switch component responsive to the limit controlsignal.

In yet another aspect of the invention, a power control system has aplurality of components including a first control component having aplurality of first component versions, a second control component havinga plurality of second component versions, and a system integrationcoupling mechanism for mechanical, electrical, and communicationcoupling the first component and the second component, wherein each ofthe first component versions being operable with each of the secondcomponent versions when coupled with the system integration couplingmechanism.

In still another aspect of the invention, a power control systemincludes a plurality of control system components and has a systemintegration coupling mechanism for mechanical, electrical, andcommunication coupling of a plurality of components into the powercontrol system, a plurality of self-identifying components and aplurality of self-configuring components. The self-configuringcomponents are configured for self-configuring in response to a receivedself-identification of another one of the plurality of components.

In another aspect of the invention, a method of controlling power in apower control system having a plurality of power control component isprovided. The method includes generating self-identification of eachcomponent within a power control system, comparing the identity of eachcomponent as self-identified to a at least one of a predeterminedconfiguration and a profile, and reconfiguring a characteristic of oneor more components responsive to the comparing.

In still another aspect of the invention, a power control systemincludes a base having a housing configured for releasably receiving acontrol unit and a cavity within the housing for receiving a powerswitch. The base includes an input power terminal for coupling to aninput power source, an output power terminal for coupling to a powerreceiving load, and coupling fixtures for fixedly and electricallycoupling to input and output power terminals and control terminals ofthe received power switch. A control unit is configured to control thepower switch for selectively providing, at least a portion of, the powerreceived at the input power terminal to the output power terminal. Thecontrol unit has a housing adapted to be releasably coupled to the basehousing and the control unit and base are each configured toelectrically couple the control unit to the control terminals of thereceived power switch as a function of the control unit being coupled tothe base.

In another aspect of the invention, a power control system includes abase having a housing for releasably receiving a control unit anddefines a first cavity for receiving a power switch, a second cavity forreceiving a limit switch, an input power terminal, an output powerterminal coupled to receive switched power from an output terminal areceived power switch, and control couplers for coupling to an input andan output control terminal of the received power switch, and a pluralityof electrical connections. A limit switch is positioned within thesecond cavity and is coupled by a portion of the electrical connectionsin series with the input power terminal, an input terminal of thereceived power switch received within the first cavity, and the outputpower terminal. A control unit is configured to generate contactorcontrol signals to the limit switch and switch control signals to thepower switch for selectively providing, at least a portion of, the powerreceived at the input power terminal to the output power terminal. Thecontrol unit has a housing adapted to be releasably coupled to the basehousing and the control unit and base are configured to electricallycouple the control unit to the control terminals of the received powerswitch as a function of the control unit being releasably coupled to thebase. The control unit includes a limit component having a thresholdlimit function and the contactor control signals are generated as afunction of the threshold limit function.

In still another aspect of the invention, a power control assembly foruse in an integrated power control system has a base with a housing thatdefines a cavity adapted for receiving a power switch. The controlassembly includes a control module configured for generating controlsignals for controlling the power switch for selectively providing powerto a load. A control housing houses the control module and is adapted tobe releasably coupled to the base housing and is configured forelectrically coupling to control couplers on the base housing forproviding the generated control signals to the power switch within thehousing cavity upon coupling the control housing to the base housing.

In yet another aspect of the invention, a method of assembling a powercontrol unit includes inserting a power switch into a cavity defined bya base having housing, coupling an input power terminal to an inputterminal of the power switch, coupling an output power terminal to anoutput terminal of the power switch, coupling a first control attachmentfixture to a first control terminal of the power switch and coupling asecond control attachment fixture to a second control terminal of thepower switch. The method also includes inserting a control unit having acontrol housing onto the base housing where the control housing and thebase housing are each configured for releasably coupling the insertedcontrol unit to the base. The method provides that the inserting acontrol unit includes compressively coupling the control unit to thefirst control attachment fixture and the second control attachmentfixture and completing an electrical connection between the control unitand each of the control terminals of the power switch.

Further aspects of the present invention will be in part apparent and inpart pointed out below. It should be understood that various aspects ofthe invention may be implemented individually or in combination with oneanother. It should also be understood that the detailed description anddrawings, while indicating certain exemplary embodiments of theinvention, are intended for purposes of illustration only and should notbe construed as limiting the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings.

FIG. 1 is a block diagram illustrating one typical discrete componentpower control system for a thermal loop.

FIG. 2A is a circuit diagram of another typical discrete componentcontroller for regulating a power switch.

FIG. 2B is a block diagram of the functional elements of a typical powercontroller.

FIGS. 3A and 3B are circuit diagrams illustrating a power control systemfor providing power to a heater that includes a current transformer formeasuring the current of the provided power to the heater.

FIG. 4 is a wiring diagram of a typical discrete component heater powercontrol system.

FIG. 5A is a block wiring diagram of a typical power control system.

FIG. 5B is a block wiring diagram of a power control system according toone exemplary embodiment of the invention.

FIG. 6 is a block circuit diagram of a power control system having asingle control module controlling a plurality of power controlassemblies according to one exemplary embodiment of the invention.

FIG. 7 is a block diagram of power control system according to anotherexemplary embodiment of the invention.

FIG. 8 is a block wiring diagram of another power control systemaccording to another exemplary embodiment of the invention.

FIG. 9 is an exploded view of a thermal power control system showing theintegration of a control component within a power control systemaccording to another exemplary embodiment of the invention.

FIG. 10 is a block diagram of a power control system showing theintegrated communication system in the components of the power controlsystem according to another embodiment of the invention.

FIG. 11 is a graphic image of a plurality of scalable user interfacesfor scalable control of the power control system according to variousexemplary embodiments of the invention.

FIG. 12 illustrates block diagrams of various user interfaces andscalable control systems according to various exemplary embodiments ofthe invention.

FIGS. 13A and 13B are block diagrams illustrating a compression couplingmechanism for a power control system according to one exemplaryembodiment of the invention.

FIGS. 14A and 14B are side perspectives of a integration and couplingsystem for compression coupling to a solid state relay having a hockeypuck configuration according to another exemplary embodiment of theinvention.

FIG. 15 is a block diagram of a hockey puck solid state relay contactoraccording to one exemplary embodiment of the invention.

FIG. 16 is a block wiring diagram of a power control system with a powerbus and a communication bus for providing single phase or dc poweraccording to another exemplary embodiment of the invention.

FIG. 17 is a block wiring diagram of a power control system with a powerbus and a communication bus for providing two phase power according toanother exemplary embodiment of the invention.

FIG. 18 is an exploded side perspective view of a power control moduleaccording to one exemplary embodiment of the invention.

FIG. 19 is a side perspective view of a power control assembly of FIG.18 configured for coupling to a base housing according to anotherexemplary embodiment of the invention.

FIG. 20A is an exploded side perspective view of a base housing adaptedto receive a hockey puck configured solid state relay according toanother exemplary embodiment of the invention.

FIG. 20B is a top view of the base housing of FIG. 20A according to oneexemplary embodiment of the invention.

FIG. 21 is a side perspective view of the control unit of FIG. 18coupling to a base housing configured with a contactor and hockey pucksolid state relay according to another exemplary embodiment of theinvention.

FIG. 22 is an exploded view of a base housing as shown in FIG. 18according to one exemplary embodiment of the invention.

FIG. 23 is a block diagram of a control communication scheme for a powercontrol system according to one exemplary embodiment of the invention.

FIG. 24 is a story board illustrating a communication process flow forplug and play capabilities for a power control system according to oneexemplary embodiment of the invention.

FIG. 25 is a block diagram of an input/output data table for a powercontrol system according to another exemplary embodiment of theinvention.

Corresponding reference characters indicate corresponding partsthroughout the several views of the drawings.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following description is merely exemplary in nature and is in no wayintended to limit the invention, its applications, or uses.

One embodiment of the invention is a power control system having a powercontrol unit that includes a plurality of power control components. Thesystem includes a unit integration coupling mechanism for mechanical andelectrical coupling of a plurality of components into a power controlunit. The system also includes a communication link configured toprovide a communication among a plurality of power control systemcomponents utilizing the coupling mechanism. The system further includesa power switch component adapted for coupling by the unit integrationcoupling mechanism. The power switch component selectively provideselectrical energy to a power load. The power switch includes a powersupply interface for receiving power from a power supply, a power loadinterface for providing, at least a portion, of the received supplypower to the power load. It also includes a power switch communicationinterface configured to communicate over the communication link. Thepower switch component is adapted to the coupling mechanism formechanical, electrical and communication coupling. The system alsoincludes a power controller component for controlling the power switchcomponent. The power controller component has a controller communicationinterface for communicating over the communication link to the powerswitch component

Another embodiment of the invention includes a power control systemhaving a plurality of components, including a system control componentfor providing a control signal. The system also includes a communicationlink configured for providing a communication between at least two ofthe plurality of power control system components. The system furtherincludes a power control unit including a plurality of power controlcomponents and a unit integration coupling mechanism for mechanical andelectrical coupling of the components of the power control unit. Thepower control unit includes a power supply interface for receiving powerfrom a power supply and a power load interface for providing, at least aportion of, the received supply power to a power load. A power switchcomponent selectively provides electrical energy to a power loadresponsive to the control signal and adapted to the coupling mechanism.The power switch component includes a power switch communicationinterface configured to communicate with the communication link and alimit component for controlling the delivery of the supply power to thepower switch component. The limit component includes a limit sensor forsensing a limit operating characteristic. The delivery of the supplypower to the power switch component being responsive to the sensed limitoperating characteristic.

In yet another embodiment, the invention includes a power control systemincluding a system integration coupling mechanism for mechanical,electrical, and communication coupling of a plurality of components intothe power control system. The system also includes a plurality ofself-identifying components and a plurality of self-configuringcomponents. The self-configuring of each component being responsive to areceived self-identification of another one of the plurality ofcomponents.

In still another embodiment, the invention includes a power controlsystem including at least a first and second control component, a firstcontrol component having a plurality of first component versions and asecond control component having a plurality of second componentversions. Also included is a system integration coupling mechanism formechanical, electrical, and communication coupling the first componentand the second component, wherein each of said first component versionsbeing operable with each of said second component versions when coupledwith said system integration coupling mechanism.

Another embodiment of the invention includes a power control systemincluding a contactor power switch for selectively providing power froma power supply to a power load. The system also includes a limitcomponent with a threshold limit for providing a limit switchingfunction as a function of the threshold limit. The limit component andthe contactor power switch are configured as an integrated switch andlimit component of the power control system. The system further includesa system integration coupling mechanism for mechanical, electrical, andcommunications coupling of the integrated contactor switch and limitcomponent into the power control system. The system also includes acontrol component that provides control signals to the switch and limitcomponent for controlling an operation of the switch and limitcomponent.

In yet another embodiment, the invention is a method of controllingpower in a power control system having a plurality of power controlcomponent. The method includes generating self-identification of eachcomponent within a power control system. The method also includescomparing the identity of each component as self-identified to at leastone of a predetermined configuration and a profile and reconfiguring acharacteristic of one or more components responsive to the comparing.

Referring now to the figures, FIGS. 5A and 5B illustrate a comparison ofthe typical power control system and a power control system according toone exemplary embodiment of the invention. Similar to the power controlsystem 100 of FIG. 1, a power control system 500A of FIG. 5A includes afirst discrete power control assembly 501A that receives supply power109A from power supply 108A via the power supply input 106A and a seconddiscrete power control assembly 501B receives supply power 109B frompower supply 108B. Fuses 116A and 116B (or any similar fuse link such asa circuit breaker, by way of example) receive the input power 109A and109B, respectively and provide the received power to the coupled powerswitches 118A and 118B. The power switches 118A and 118B are discretelycoupled to the controller 102 which is equipped with a controlcomponent, such as a proportional integral and derivative (PID) controlalgorithm. The controller 102 provides control signals 511A and 511B tothe power switches 118A and 118B, respectively, for selectivelycontrolling the switching operation thereof. The controller 102 iscoupled to sensors 104A and 104B and receives sensor signals (not shown)from sensors 104A and 104B as an input to generating the control signals511A and 511B. The first power load 120A and second power load 120B arecoupled to their associated power switches 118A and 118B to selectivelyreceive the provided power from the associated power switch 118A and118B. As each of the components are separate components, each much beseparately wired or connected together. The power control system 500Ahas two sets of discrete power control assemblies 501A and 501B forproviding power to two power loads 120A and 120B and requires at least28 wire terminations 124, each of which requires initial installationand ongoing maintenance.

In contrast, FIG. 5B illustrates a power control system 500B accordingto some embodiments of the invention that includes a controller 501 andtwo integrated power control assemblies 502A and 502B for providingpower to power loads 120A and 120B, respectively. Each power controlassembly 502 includes a unit integration coupling mechanism formechanical and electrical coupling of the various components into anintegrated power control assembly 502. Such a unit integration couplingmechanism can take many forms. For example, in one embodiment, a unitintegration coupling mechanism can include one or more housingsconfigured with interlocking features and couplers for mechanicallyengaging the various components and for establishing and maintainingnecessary electrically connectivity, and, where desired, communicationsconnections. In other embodiments, such coupling and connectivity isconfigured for pluggable or releasable coupling such as through snapcouplers, compression contacts, etc. In other embodiments, the unitintegration coupling mechanism for an integrated power control assembly502 could be a plurality of housings configured for interlocking andinterconnection for a common mounting such as a rail or morespecifically, a DIN rail mounting system. In various embodiments, theintegrated power control assembly would include an assembly that couplesvertically and/or horizontally, but within a reduced footprint and withfewer external or required wiring connections, due at least in part, tothe integration coupling mechanism with integrated and mated electricalconnections.

As shown, the power control assemblies 502A and 502B have a singleinterface to a remote controller 501 via a control link or communicationbus 507. Each of the power control assemblies has a control businterface 505A and 505B for interfacing with the communication bus 507and to the controller 501. Each of the power control assemblies 502A and502B includes an integrated power switch controller 504A and 504B thatare shown as including a proportional, integral, derivative PID controlcomponent, by way of example. The power switch control function can bePID control but can be in any method or system for controlling theoperation of the power switch, including but not limited to adaptive PIDcontrol, proportional control, a proportional/integral control, aproportional, integral, two derivatives (the second being foracceleration) (PIDD) control, feed forward, feedback, by way of example.Each power switch controller 504A and 504B is coupled within the powercontrol assembly 502 by an internal integrated interface 506A and 506B.The internal integrated controller to power switch interface 506 canprovide for a mechanical and electrical coupling of the power switchcontroller 504 to the power switch 118 located within the power controlassembly 502. Similarly, a fusible link 516A and 516B, such as a fuse orcircuit breaker, by way of example, can be within the power controlassembly 502 in which case a fusible link to power switch interface 508Aand 508B can provide for the mechanical and/or electrical coupling ofthe fusible link 516 to the associated power switch 118. Additionally,the power control assembly 502B can also include an integrated sensor104B via an integrated internal interface 512. In other embodiments, anexternal sensor 104A can be coupled to the integrated power switchcontroller 504A via a sensor interface 510.

Generally, the integrated power control assembly 502 can have one ormore components such as the power switch controller 504, the fusiblelink 516, the power switch 118, sensor 104, and associated internalinterfaces 506, 508, and 512, all of which are integrated into a powercontrol assembly 502 that provides for a reduced footprint and fewerwired connections. While not shown in FIG. 5B, one or more integratedpower control assemblies can also include other integrated componentssuch as a second power switch (for example a contactor or mechanicalrelay), a power measurement component, a limit component, a currentsensing component, etc. These can also be included in a similar manneras the illustrated power switch controller 504, the power switch 118(shown as a solid state relay (SSR)), and fusible link 516 into andwithin a combined or single operating unit for controlling and providingpowering to one or more power loads 120.

Additionally, one or more power control assemblies 502, such as shown as502A and 502B, can include an internal integrated proportional,integral, and derivative (PID) control function for internal operationalcontrol and for communication to a controller 501 or with each otherover the common communication bus 507. The controller 501 cancommunicate with both power control assemblies 502A and 502B or one ormore components thereof, without requiring separate or dedicatedconnections or wire terminations between the components of each powercontrol assembly 502. As such, the power control system 500B requires 13wiring terminations 124 for each control assembly, which is a beneficialreduction from the 28 for each discrete control arrangement required inpower control system 500A of FIG. 5A.

As will be discussed, the controller 501 and/or the control component504 can include a user interface (UI) module, an input/output module,and a communication module (not shown in FIG. 5B). Additionally, one ormore modules within a power control assembly 502 or an integrated powercontrol system 500 can include a processor or processing module (notshown) for one or more operations thereof. One or more of theseprocessing modules can include a processor, memory, firmware, hardware,and/or software. The processing modules can also include an algorithm, aneural network, empirical data, numerical data, fuzzy logic, a neuralfuzzy circuit, a residual life algorithm, an artificial intelligencemodule, a modeling module, and a statistical function.

Each memory can be any type of memory for storing data and/or softwareincluding EPROM, EEPROM, a virtual storage location on a network, amemory device, a computer readable medium, a computer disk, and astorage device operable to communicate information.

As one or more components is configured with a processing module thatincludes memory, these components provide for new and improvedfunctionality within each component and among components of the powercontrol system and with other operational or control systems, as will bediscussed further herein and as will become enabled to those skilled inthe art after comprehending the invention as described herein. Forexample, each component memory can store component configurations,system profiles or configurations, diagnostic data, diagnosticoperations, and other operational data. Additionally, operatingcharacteristics, events, status, failures, modes, and states, by way ofexample, can be stored related to one or more operations of thecomponent, a module, or another component within the power controlsystem. As just one example, a plurality of stored configurationsenables the component to reconfigure to adapt to newly or changedcomponents within the power control system. In one embodiment, acomponent can initiate or activate a feature not previously supported byanother component or within the assembly, but which is now available dueto a change within the power operating system. Such a change can includea software update or a change out or addition of a component.

Referring now to FIG. 6, a power control system 600 includes many of thesame components and power control assembly features and functions, whichare not repeated here. However, the power control system 600 furtherillustrates embodiments of the invention wherein the controller 501 thatis connected to the communications bus 507 and thereby coupled to powercontrol assemblies 502A and 502B, can include a user interface 602 forreceiving or providing information and input to and output from a user.This can be any type of user interface, including, but not limited to, akeyboard, a mouse, a control panel, one or more buttons, a touch screen,and a voice input. A communication module 604 provides forinterconnectivity and interoperability via a remote network oroperational system 606 for control reporting, input, andinteroperability for coordinated control of one or more processes oroperations. An input/output module 610 can also provide for directconnected inputs or outputs that may be desired or required for aparticular user application. These may include an interface forcontrolling a power switch that is not compatible with or coupled to thecommunication bus 507, or one or more sensors as described herein.

An expansion bus module 608 provides for interconnectivity with thecommunication bus 507 for coupling and communication with one or moreintegrated power control assemblies 502 and possibly other components,such as sensors, by way of example, that can be coupled to thecommunication bus 507. The communication protocol of the expansion buscomponent 608 can be adapted to be compatible with any type ofcommunication bus 507 within the power control system 600, or moduleswithin the power control assembly 502 therein. As noted above, thecommunication bus 507 or link can also provide for communication betweentwo or more power control assemblies 502, or between the power controlassembly 502A and power control assembly 502B, or components and modulesthereof. The communication link and interface can be any communicationsystem including a hard-wired, optical or wireless facility. Thecommunication link and component communication interfaces can becompatible with a WatBus™, Dallas Semiconductor one-wire protocol,Seriplex, sensorbus, DeviceNet™ bus, FMS, Lon Works, Control AreaNetwork (CAN), Interbus S, SDLC, AS-Interface (AS-i), Local Interconnectbus (LIN-bus), EEE-1118 bus, Profibus, Modbus RTU, an enterprisecommunication bus including an Ethernet TCP/IP, the Internet, a tokenring LAN, an Ethernet LAN, an FDDI network, a private data network, anISDN, and a VPN, by way of example.

The communication bus 507 can be a two-way communication facility thatprovides for increased integration and centralized control andconfiguration of the components within the power control system. Thecommunication can include status, commands, alarms, indicators,messages, software, system profiles, configurations, parameters, andcharacteristics associated with the operation, control, sensing, ordiagnostics functions of the one or more components or modules of thepower control system. By way of example and as will be discussed below,the communication bus 507 provides for communication of softwaredownloads, storage, changes and recalling of a stored profile orcomponent configuration. In some embodiments, the communication bus 507interfaces with processing systems contained in one or more componentsof a power control assembly 502 for operational integration andcombination of power control loop characteristics, parameters, data andvariables, and can enable improved administration and operational datafrom the power loop to the controller and to remote administration andmanagement systems. Additionally, the power control assembly 502 withits integration coupling mechanisms and integrated communication bus 507provides for application specific control schemes, methods, profiles,configurations, and operations so that the power control system 600 canbe customized and adapted to one or more user applications.

As will be discussed below, an integrated power control assembly 502 isa common integrated configuration or assembly containing a plurality ofpower control system components. In many embodiments, one or more powercontrol components are not integrated within the power control assembly502 that is in or near the user application, but is remotely located foreasy access by a user. However, in many embodiments, the majority ofpower control system components are contained within or associated withthe power control system 600 or one of the power control assemblies 502.

As noted above, the power control assembly 502 can include any componentassociated with providing power to a power load in a variety of userapplications. As one example of a power control assembly 502 or system600 for providing power to a heater application, the power controlassemblies 502 can include a plurality of components in a thermalcontrol loop. These can include components for a process sensor, atemperature/over temperature controller, current sensor or transformer,switch/relay/contactor, a fuse, a limiter, a limit sensor, and a powerload. As illustrated by way of example in FIG. 6, the power controlassembly 502A includes a power switch 612 (similar to 118 above) thatmay be a solid state relay, silicon controlled rectifier, a mechanicalrelay, or contactor (by way of example, and a limit component 614 in atower-like integrated power control assembly 502A and/or 502B. The powercontrol assembly 502A in FIG. 6 includes an interface 505A forinterfacing to the communication bus 507 and a power receiving interface106A to the limit component 614 for interfacing with the power supply108A. In the alternative or in addition, as with the power controlassembly 502B, a fusible link 516 can be included. The fuse link 516 canbe a fast blow fuse or a circuit breaker, by way of example, forprotecting the power control switch 612B. The power control assembly502A also includes the power switch 612A that is shown to include anintegrated PID control function. In the alternative, a separate controlcomponent 504 and power switch 612 can be included or can be combinedvia an integration coupling mechanism such as a housing. In the powerswitch control assembly 502A, a power switch control function is shownas a PID control for controlling the power switch 612A and therebyproviding power to the power load 120A (shown as a resistive heater).The power switch 612A can further include, as in this example, a processsensor interface 510A for interfacing with the sensor 104A (shown as atemperature sensor). Similar features, interfaces and coupling alsoapply to the second power control assembly 502B. Additional powercontrol assemblies 502 can also be coupled to the communication bus 507and coordinated by the controller 501.

As illustrated in FIG. 7, in some embodiments a controller 501 can becommunicatively coupled to one or more integrated power controlassemblies 701A, 701B, and 701C via the communication bus 507. As shown,integrated power control assembly 701A does not include an integratedpower switch control component but includes a power switch 118A with twopower switch control terminals 119A and 119B. The input/output module610 of the controller 501 provides a power switch control signal 706 forcontrolling the power switch 118A. The input/output module 610 alsoincludes an interface for receiving a sensor signal 708 from the sensor104A associated with the heater or power load 120A. The power controlassembly 701A also includes a power measurement component 702A formeasuring the power provided to/from the power control assembly 502A.The power measurement component 702A can include one or more sensors ortransducers 704A associated with an internal power bus of the powercontrol assembly 701A and can measure various electrical characteristicsfor determining a measurement of power as are known to those skilled inthe art. A limit switch or limit component combination 614A is alsoincluded and is responsive to the limit sensor 114A for providing anoperational limit as is known in power control systems.

In the power control assembly 701B and 701C of FIG. 7, an integratedpower switch control component or module 710B and 710C are coupled topower switches 118B and 118C, respectively, for controlling theassociated power switch. The power control assembly 701B includes apower measurement component 702B with one or more power measurementtransducers 704B. Additionally, the power control component 710Bincludes the interface 510 for receiving input from the sensor 104B forcontrolling power switch 118B. The power control assembly 701C differsin that it includes a fusible link 516C but does not include a powermeasurement component 702 or a limit component 614. However, powercontrol component 710C is configured to include an integratedtemperature measurement component 712 that can be configured fordetermining the temperature of the power load 120C by measuring one ormore electrical characteristics of the power on the output of the powerswitch 118C.

As illustrated in the power control system 700 having three exemplarypower switch assemblies 701A, 701B, and 701C, each can include a varietyof components, but includes, at least in some manner, an integratedassembly that provides for interconnectivity and interoperability withminimal user interaction such as hard-wiring connections 124 (as shownas a small circle with a line). Each of the components of each powercontrol assemblies 701 is operationally and physically coupled by apower control assembly mechanical and electrical coupling mechanism withinterfaces as will be discussed in more detail below. Also, thecommunication bus 507 is configured for communication between each powercontrol assembly 701 and the power controller 501, other power controlassemblies 701 and other coupled components 714 that are coupled to thecommunication bus 507.

FIG. 8 illustrates another embodiment of a power control system 800having a controller 501 connected to three power control assemblies801A, 801B, and 801C, shown as functional blocks. The power controlsystem 800 is similar to many of the same and similarly marked systemcomponents as shown in power control system 500B of FIG. 5B, powercontrol system 600 of FIG. 6, and power control system 700 of FIG. 7,and therefore a description of each of these components will not berepeated here. However, the power control system 800 illustratesadditional embodiments that include a mechanical relay 802 as the powerswitch in power control assembly 801A, and a current transformer 806B asa power saving component of the power control assembly 801B. The currenttransformer 806B can provide for monitoring the power received from thepower source.

Additionally, an internal control bus 804 (shown as 804A, 804B, and804C) is provided in each of the power control assemblies 801A, 801B,and 801C. In these arrangements, the communication bus 507 interfaceswith the control modules 504A, 504B, and 504C via the communicationsinterface 505A, 505B, and 505C, respectively, for providing andreceiving communications such as control data and information. However,as illustrated each of the power control assemblies 801A, 801B, and 801Cis configured with an internal communication bus 804 for communicatingwithin and between the various components of the power control assembly801. The internal communication bus 804 can be integral to theintegration coupling mechanism, such as through connectors andconnections within a housing or via contacts that electrically coupletogether upon the assembly of the power control assembly 801. Forexample, the internal communication bus 804 connectivity can beautomatically connected upon the releasable coupling of a housingcontaining the mechanical relay 802 and the power switch controlcomponent 504A of power control assembly 801A. In this manner, theintegrated operational features and functionality as provided betweenthe controller 501 and with and/or between each of the power controlassemblies, can be further integrated as an internal communication andcontrol facility between components within a single or between one ormore power control assemblies 801. In such embodiments of a powercontrol system and power control assemblies, any communication receivedby the power switch control module 504 can be relayed or communicatedinternally within the power control assembly 801.

From this, it can be seen that additional power control componentswithin each power control assembly 801 can be easily added and removedand still ensure connectivity and interoperability. Based on a desireduser application, one or more power switch control components 502, powerswitches 118, sensors 104 and 114, power loads 120, alarms (not shown),events (not shown) and auxiliary functions (not shown) can be added asneeded without requiring substantial rewiring or manual manipulation ofthe individual components within the integrated power control assembly801.

Referring now to FIG. 9, in some embodiments the controller 501 can alsobe integrated or at least mated to the power control assembly 801 byintegrated mating contacts 902. The mating contacts 902 can be such thatwhen the controller 501 is mounted adjacent to the power controlassembly 801, a mating and coupling is accomplished without requiringmanual user connection activity. In the illustrated example of FIG. 9, aDIN rail mounted temperature controller 501 operably mates with thepower control assembly 801 via mating contacts 902 to form an integratedpower control system 901. In some embodiments, the mating contacts 902may be one or more pluggable connectors.

FIG. 10 is a block diagram of a power control system 1000 having anintegrated communication system according to some embodiments of theinvention. The power control system 1000 includes one or morecommunications buses 507 that provide for communication connectivitybetween various similar and dissimilar components and power controlassemblies 502 comprising a system for controlling power in a powercontrol operation such as a processing operation, by way of example.This exemplary embodiment is not intended to illustrate a particularlayout or arrangement for the components or modules of the power controlsystem. As illustrated in FIG. 10, a communication link or bus 507 maybe any form of communication facility and in one example, is a WatBus™.A user interface (UI) 602 can be included and can communicate via thecommunication bus 507 or can communicate via a fieldbus communicationfacility (not shown). The user interface 602A is shown, by way of thisexample, as a touch screen 1002, but can be any form of interfacereceiving a user command or input. Other examples include a keyboard, amouse, a touchpad, a voice input, and a data input and is illustrated byway of example as user interface 602B. One or more power switches 118 orswitching components can also be connected to the communication bus 507as is shown as solid state relays (such as ones known as a hockey puckSSR 118), DIN rail mounted power control assemblies 1005, andDIN-A-MITE™ contactor 1006 or contactor configured for coupling to a DINrail 1008. A control component such as a DIN controller 1010 can also beconnected via the communication bus 507. A display module can provide auser with displayed information regarding the power control system. Oneor more power switch components (illustrated as DIN rail mountedcontrols) and a communication module 604 can also be connected to thecommunication bus. Also as shown, the DIN rail mounted power controlassemblies 1005A-N can be fully integrated control assemblies such asintegrated power control assemblies 701, 801 and 901 with integratedcomponents and modules.

Each component within the power control system is configured or adaptedfor plug-and-play within the power control system. Additionally, moduleswithin a component can also be configured for plug-and-play. FIG. 11illustrates one exemplary set of interchangeable control modules 501A-Nwherein each contains a user interface having different functionality ornone at all as in the case of a factory programmed unit. Each of theplurality of control components within the power control system familyof components can contain different modules or functionality. Each ofthe user interfaces of 501A-N can be adaptable for optional inclusioninto embodiments of the system. As noted, the user interface can simplybe status lights or LEDS, can be a seven segment display with a rotaryknob for user selection and input, can include input keys, or caninclude a LCD display. The particular selection of each is at the userdiscretion based on the application needs as each of these embodimentsis compatible with each of the other modules and components within thepower control system. As illustrated, each can be of a different sizeand require a different number of connectors; however, they are stillcompatible within the power control system in a plug-and-play manner.

However, each and every one of the control components is compatible witheach and every other component and each and every other member of acomponent family within the power control system. As such, asillustrated in FIG. 11, embodiments of the invention provide forscalable configuration of the control module 501 so as to adapt to theuser environment. Additionally, each can be replaced by another, therebyproviding for each modification and adaptation by the user.

Another aspect of various exemplary embodiments of the invention isscalability. For example, the communication module 604 can include aplurality of communication interfaces and a plurality of communicationbuses 507 or loop configurations. As such, the control component 501 isscalable to meet the requirement of the particular user applicationwithout requiring a separate or different control component. The controlmodules such as a particular communication interface card can be adaptedto the particular design or application without requiring a replacementor substitution of the control component or module 501.

FIGS. 12A-E illustrate various arrangements of a power control systemaccording to various embodiments of the invention. In one exemplaryembodiment, a power control system 1202 is a predetermined or minimumconfiguration (MC). Such minimal configuration 1202 can also be used inconjunction with a simple user interface 602 as in 1204, a power switchcontroller 504, and can include an alarm indicator such as a light or aflag (not shown). As in FIG. 12C, the system 1206 has two or moreminimal configurations 1202 that are implemented with a common userinterface. In FIG. 12D, a minimal configuration 1202 is combined with auser interface 602 and a communication module 604 to form a system 1208.In FIG. 12E, a plurality of minimal configurations 1202 are combinedwith a single user interface 602 and a single communication module 604.

As discussed above, various embodiments of the invention include a powercontrol assembly integration mechanism such as a housing for couplingthe system components as an integrated assembly. As also mentioned, insome embodiments the components or modules of the power system or apower control assembly are configured to mechanically connect withsnap-in or pluggable connectors, or housings that are adapted tomechanically and electrically couple the components into a singleintegrated assembly. In some embodiments, each component within a powercontrol assembly can comprise a separate layer, or a portion of a layer,such that the portion is configurable with another portion and thecombination of the one or more portions substantially comprise one ofthe pluralities of layers. Of course, layers can be vertical orhorizontal in practice, and may be combined in a single embodiment.System and methods for operationally combining these components into anintegrated power control assembly will now be described and illustrated.

In some embodiments, a unit integration coupling mechanism provides formechanical, electrical, and communication coupling of each componentwithin the power control assembly. The unit integration couplingmechanism can provide a mechanical connectivity between two or morecomponents that couples two units together in a fixed or in a biasedarrangement. In one embodiment, a biased coupling can be provided by acam locking system or means, one exemplary embodiment of which isillustrated in FIGS. 13A and 13B. As shown in FIG. 13A, a four componentpower control assembly 1300 has three layers 1302A, 1302B, and 1302C,with the first layer 1302A having a component 1304, the second layer1302B having two components 1306 and 1308, and the third layer 1302Chaving a single component 1310. As shown, two locking mechanisms 1314Aand 1314B are positioned to couple all three layers top and bottom ofthe power control assembly layered-stack and through a bottom or unitmounting plate 1311. Two cam devices 1312A and 1312B are attached to thetwo locking mechanisms 1314A and 1314B at the top. In such anarrangement, the four components can be removed from the power controlassembly 1300 when the can devices 1312A and 1312B are unlocked.

FIG. 13B illustrates each of the cams 1312A and 1312B in a lockedposition about the locking mechanisms 1314A and 1314B. In thisarrangement, the two locking cams 1312A and 1312B at the top have beenrotated to a locked position. When the two locking mechanisms 1314A and1314B are in a locked position, the four components 1304, 1306, 1308 and1310 are mechanically and operationally coupled as a single powercontrol assembly 1300. In this exemplary embodiment, the lockingmechanisms 1314A and 1314B and/or the cam devices 1312A and 1312B can becomprised of a solid constructed material or can be comprised of anelastic material. When an elastic material is used, the lockingmechanisms 1314 provides a bias or compression force such that the fourcomponents 1304, 1306, 1308 and 1310 are compressed together. Thecompression force provides for continuous coupling without requiringuser intervention or adjustment during operation and reduced operatormaintenance.

Another type of power control assembly integration coupling mechanismincludes a biased or compression coupling (not shown). For example, athreaded device having a shoulder to limit insertion of the threadeddevice and a spring. In operation, one or more threaded devices can beutilized as a unit integration coupling mechanism to provide thecontinuous bias or compression force to the components of the powercontrol assembly. Each threaded device is configured such that thedevice is inserted to the shoulder and cannot be inserted further,thereby limiting over-tightening by a user during installation. Thedevice can be configured such that when the device is inserted to theshoulder, the spring is at least partially compressed. In oneembodiment, the spring is only partially compressed. As such, the springapplies the compression force to operably couple the components withinthe power control assembly. The continuous compression force eliminatesterminal or connection heating often caused by connection resistance orloose connections.

As noted, the unit integration coupling mechanism while described as amechanical coupling, also provides electrical coupling between two ormore components of a power control assembly. The electrical coupling canresult from the mechanical coupling and bias applied by the unitintegration coupling mechanism. The electrical coupling of the supplypower, load power, communication links, and unit operational power isprovided by inter-component couplers configured into each unit componentsuch that when the coupling is actuated, the necessary electricalconnections are completed. Additionally, in the embodiment utilizing acompression or bias unit integration coupling mechanism, the connectionsare biased to ensure continuous connectivity of the connections. Inother embodiments, the electrical connections are made separately butenabled by the mechanical coupling. For example, in one embodiment, anelectrical termination assembly or mechanism between components within apower control assembly can include a compression contact of a surfacethat can be made with a clip receptacle having a spring-type acting on ablade portion of an adapted connector. Such an arrangement can alsoprovide for mechanical self-alignment of the various components duringinstallation.

As noted above, in particular embodiments, two or more housings can beadapted for providing the mechanical coupling of the power controlassembly integration coupling. Additionally, the housings can beconfigured to include electrical connections that are mated or connectedupon the mechanical coupling of the two or more housings.

One example of such a biased inter-component connection is illustratedin FIGS. 14A and 14B. In this exemplary embodiment, a power controlassembly 1400 is configured to include a solid state relay (SSR) 1402,such as a well known one having a hockey puck configuration. Awell-known hockey puck configuration SSR is illustrated in FIG. 14Ahaving dimensions including a 2.3″ square. The hockey puck SSR 1402 hasfour screw seats 1404 for receiving a screw and wire clamping device(not shown). Two of the screw seats 1404 are for control leads forreceiving a control signal for operating the SSR 1404 as a switch andtwo are for receiving and providing supply power. Four ball posts 1408are positioned to couple to the four screw-seats 1404 of the SSR 1402.The posts 1408 can couple to a limit component 1406 providing a limitswitching function to the SSR 1408. A PID controller 1410 component iscoupled to the limit component 1406 thereby providing control functionsto the operation of the SSR 1402. As shown, the PID controller 1410 andlimit component 1406 within the illustrated SSR power control assembly1400 are proportionally dimensioned and configured for a stackableengagement and coupling to the hockey puck SSR 1402 without changes tothe SSR configuration or design. Additionally, the SSR 1402 and theother components of the power control assembly 1400 do not requireconnections or wiring other than that provided by coupling of the threecomponents together with a compression force provided by theinter-coupling arrangements.

To accomplish this, the screw and wire clamp are removed (as illustratedin FIG. 14) and a ball-ended post 1408 of the limit component 1406 isbiased to engage the screw seat 1404. As illustrated, the limitcomponent 1406 and/or switch control component 1410 of the power controlassembly 1400 is equipped with the ball post 1408 that, when biased as apart of the unit integration coupling mechanism, is compressed into thescrew seat 1404 of the SSR 1402, thereby completing an electrical poweror electrical control connection with the SSR 1402. The power controlassembly 1400 provides the compression force such as to apply acompressed electrical coupling to the SSR 1402 consistent with standardSSR pressure placement and arrangements and specifications. These can beto just the control inputs to the SSR 1402 or can be to the electricalpower input and output leads of the SSR 1402.

FIG. 14 illustrates the power control assembly 1400 wherein the limitcomponent 1408 is operably coupled to and positioned between the SSR1402 and the switch control 1410. In this exemplary embodiment, thelimit component 1406 includes a supply power connector for receiving thesupply power from a power source. The switch control 1410 includes a PIDalgorithm, by way of example, for controlling the SSR 1402 as a powerswitch. The switch control 1410 is operably coupled to the two controlleads of the SSR 1402, the connection being made in this embodimentthrough the limit component 1406. In another embodiment, theconfiguration of switch control 1410 and the limit controller 1406 canprovide for the limit component 1406 to connect directly to the twosupply power screw-seats 1404 of the SSR 1402 and the switch control1410 can connect directly to the two control screw-seats 1404 of the SSR1402.

Typically, a power switch such as the SSR 1402 is thermally coupled to aheat sink 1412. A switch control 1410 with PID algorithm is positionedand coupled to the SSR 1402 such that the two controller screw-seats1404 are electrically coupled to the switch control 1410 for controllingthe SSR 1402 switch. One or more printed circuit or wiring board (PCB)couples to the supply power screw-seats 1404 of the SSR 1402 and topluggable cage clamp connectors for providing supply power to a powerload (not shown). A combined limit and definite purpose contactor (DPC)component (not shown) can receive supply power from a power source andprovides power to the input supply power connection of the SSR. Theswitch control component can be arranged to allow for the coupling ofboth the switch control 1410 and the limit-DPC component directly to theSSR 1402 in an interlocking arrangement. A communication module with aWatBus™ configuration, by way of example, can be arranged to bepluggable to one or both of the switch control 1410 and limit-DPCcomponents. The communication module can be pluggable to one or both ofthe switch control 1410 and limit-DPC components and includes aninterface to the communication bus 507. Additionally, one or more sensorinterfaces (not shown) can be included to one or more of the componentswith the illustrated power control assembly 1400.

These embodiments of a power control assembly 1400 provide for improvedfield installations where the SSR component is located on a panel andthe user installs the control component and the limit component to forma power control assembly or system according to some embodiments of theinvention. Such connection assemblies can also provide for a factoryassembly where the SSR is attached to the control component and/or limitcomponent prior to shipment.

In other embodiments, one or more electrical connections can also bemade between modules of one or more components, or between components ofthe power control assembly. Supply, load, and component powerconnections can be made by pin and receptacle or biased connections, oneexample being as discussed above. Connections for inter-component orinter-module communications can also be made using a metallic or opticalinterconnection such as with a pin and receptacle arrangement, or a biasplate and contactor arrangement.

In some embodiments, connections to external components or devices fromthe power control assembly include connections that only require minimumuser interaction and input and provide for continuous post-installationbiasing. While the industry generally utilizes a simple screw and clamparrangement for attaching power supply and power load leads, these oftenloosen over time causing increased heating, arcing, and failure. Assuch, these connections are often the focus of routine maintenancerequiring the user to retighten the screw, such as a ¼ or ½ turn everymaintenance period. Additionally, external connections to the powercontrol assembly can also utilize self-biasing or compressionconnections such that various sizes or diameters of wiring can beconnected and the connections are continuously biased to ensure secureconnectivity over time. Similar as discussed above, these externalconnections can be cam-operated mechanical connection, can be biased orelastic mechanisms, or can include a spring-biased, threaded device suchas a spring-biased plunger, by way of example. In such embodiment, aspring-biased or elastic material-biased force is applied to theconnection over the life of connection, thereby providing a continuouscompression force to the connected wire even in view of aging andmovement of the wire.

FIG. 15 illustrates one exemplary embodiment of the power controlassembly system 1502 in a user application 1500. As shown, a standardsolid state relay (SSR) in an industry standard configuration isreferred to as a “hockey puck.” While the following describes a powercontrol system as applied in some embodiments, it should be understoodthat this is just one exemplary embodiment and application of variousaspects of the invention.

As shown in FIG. 15, the power control switch SSR 1402 is coupled inseries with an AC power supply input 1504 and an AC power load 1506. TheSSR 1402 receives a control input in the form of DC power 1508 from alogic controller or other DC power source 1510. A power switch controlmodule 1512 is coupled to the SSR 1402. The power switch control module1512 includes a connection for a control sensor 1514 that is positionedand configured for the AC power load 1506. Additionally, an electronicfield sensor 1518 senses the electromagnetic field output generated bythe SSR 1402.

FIGS. 16 and 17 illustrate additional embodiments of an SSR powercontrol assembly. FIG. 16 illustrates a single-phase AC power controlassembly using a hockey puck configured SSR 1402 as one of the powerswitches. FIG. 27 illustrates a two-phase AC power control arrangementusing the SSR 1402 for switching two-phase AC current. In FIG. 16, apower control assembly includes an SSR power switch 1402 componentthermally coupled to a heat sink 1602 as is known in the industry.However, the SSR 1402 is mechanically and operably coupled to one ormore other components of the power control assembly 1600. As shown, thecommunication bus 507, such as a WatBus™, provides for communicationsamong the components and therefore for controlling the operations of thecomponents within the power control assembly 1600. In this example, thecommunication bus 507 is connected to the limit component 1604, to apower switch control 504 (denoted as a PID by way of example only) andto the SSR 1402. Additionally, the communication bus 507 is alsoconnected to the power measurement component 702 that monitors the powerprovided to the power load 120. A temperature sensor (not shown) cansense the temperature of the power load 120 and provide the temperaturesensor signal (not shown) to the power switch control 504. The supplypower 109 provides single phase AC power to the limit contactor 614. Thelimit contactor 614 receives a control signal (not shown) from the limitcontactor controller 1604. The limit contactor 614 is connected to thefusible link 516 which can be a fast-blow semiconductor fusible link ora circuit breaker for protecting the SSR. When actuated by the powerswitch controller 504, the SSR 1402 provides at least a portion of thesupply power 109 to the power load 120. As illustrated in FIGS. 16 and17, each of the components of the power control assembly 1600 isintegrated into a common integrated assembly such as a “tower” builtupon the hockey puck SSR 1402. The various components of the powercontrol assembly 1600 are coupled using an integration unit couplingmechanism as described above that provides for both mechanical andelectrical coupling of each of the components.

Similarly, FIG. 17 illustrates a power control assembly 1700 forswitching two-phase AC power provided by the two phase AC power source108. The other components of the power control assembly 1700 are similarto those described above with regard to power control assembly 1600 andare not repeated here for sake of brevity.

In some embodiments of the invention, a control assembly for use in anintegrated power control system has a base including a housing anddefines a cavity within the housing for receiving a power switch. Thecontrol assembly includes a control module configured for generatingcontrol signals for controlling the power switch for selectivelyproviding power to a power load. A control housing is configured forhousing the control module and adapted to be releasably coupled to thebase housing and is configured for electrically coupling to controlcouplers on the base housing for providing the generated control signalsto the power switch within the housing cavity upon coupling the controlhousing to the base housing.

Referring now to FIG. 18, a control module 1800 is illustrated in anexploded and unassembled view. The control module 1800 includes acontrol housing 1802 having one or more flexible mating members 1804formed on the outer portion of the control housing 1802. A pair offlexible mating members 1804A are on opposing sides of the controlhousing 1802 and a pair of flexible mating members 1804B are ondifferent opposing sides of the control housing 1802. As shown, thecontrol housing 1802 defines a lower portion 1806 that may also beadapted by keying or other formations, to couple to or seat within areceiving or coupling portion of the base housing.

The control housing 1802, its lower portion 1806 and one or more sets offlexible mating members 1804A and 1804B are configured to be receivedand releasably coupled to a power control assembly base housing byinterconnecting with the flexible mating members 1804. In theillustrated embodiment, two pairs of flexible mating members 1804 areillustrated. In such an embodiment, the control housing 1802 may beadapted to fit more than one base housing such as to enable the controlhousing 1802 to be mounted in more than one orientation, e.g., to eitherengage the flexible members 1804A or the mating members 1804B. In otherembodiments, a single mating member 1804 may be adapted to couple to abase housing. Additionally, the lower portion 1806 can include one ormore keying configuration or fixtures 1826 configured to engage a basehousing adapted to selectively receive such keying fixtures 1826.

The control housing 1802 includes a cavity 1808 for enclosing one ormore control modules 1810 that can be PCB boards containing one or moreelectrical components as described above, such as, by way of example, aPID switch control component, or a limit component. The control module1810 can be retained within the cavity 1808 either horizontally 1810A orvertically 1810B. A cover 1814 can be configured for releasably couplingto the control housing 1802. As illustrated, the cover 1814 can includeone or more electrical connectors 1816 for coupling the control modules1810B to external wires, sensors, or a communication bus 507 (notshown). As shown, the cover 1814 can include one or more connectorreceiver cavities 1818 that provide for receiving at least a portion ofthe electrical connector 1816 and for enabling the electrical connectorto connect to the PCB board connectors or pins 1812 of the PCB boards1810B positioned within the cavity 1808. As illustrated, the electricalconnectors 1816 may be female connectors configured to receive male pins1812 of the PCB board connectors. In some embodiments, the connectorreceiver cavity 1818 can include individual holes therethrough forindividually receiving one of the male pins 1812. The control housing1802 and/or the cover 1814 can also include a flexible connectorretainer 1820 configured for fixedly retaining a connector 1816 once itis inserted into the connector receiver cavities 1818. In someembodiments, each PCB 1810B can include an integrated F-terminal set ofpins 1812 that can be individually mounted to the board such that thePCB board 1810B and the connector pins 1812 create an ambidextrous PCBboard. This is different than many PCB connections that are configuredfor a single right or left orientation. In this manner, one or morecontrol printed circuit boards (PCB) placed within the cavity 1808 canuniversally couple through the connector receiver cavity 1818.Additionally, in some embodiments, the connector receiver cavity 1818can include keying to selectively receive a correspondingly configuredfemale connector 1816. In this manner the connector receiver cavity 1818provides for the predetermined orientation of the female connectorwithin the connector receiver cavity 1818 and therefore to anambidextrous PCB 1810B and F-terminal pins 1812 on the board. Thecombination of these features, provide for increased operational anddesign flexibility for the power control unit and the control modules1810B therein. The control housing 1802 and or the cover 1814 caninclude a plurality of vents 1822 to enable thermal ventilation asnecessary.

In some embodiments, a horizontally mounted control module 1810A orsimilar device can provide for electrical connectivity through anopening 1823 or with an electrical contact 1824 positioned along thelower portion 1806 such as on the bottom (not shown in FIG. 18 butrepresentatively placed by arrow 1824). Such openings 1823 or electricalcontacts 1824 are configured for making electrical contact with acorresponding portion of the base housing when the control unit 1800 iscoupled to the base. Additionally, the horizontally mounted controlmodule 1810A can include one or more sensors (not shown) configured andpositioned along the lower portion 1806 to sense a characteristicassociated with the operation of the control assembly or the base onwhich the control unit 1800 is positioned.

In some embodiments of the invention, a power control system includes abase having a housing configured for releasably receiving a control unitand a cavity within the housing for receiving a solid state relay havinga hockey puck configuration. The base includes an input power terminalfor coupling to an input power source, an output power terminal forcoupling to a power receiving load, and coupling fixtures for fixedlyand electrically coupling to input and output power terminals andcontrol terminals of the received solid state relay. A control unit isconfigured to control the solid state relay for selectively providing,at least a portion of, the power received at the input power terminal tothe output power terminal. The control unit has a housing adapted to bereleasably coupled to the base housing. The control unit and base areeach configured to electrically couple the control unit to the controlterminals of the received solid state relay as a function of the controlunit being coupled to the base.

In some embodiments of the invention, a control assembly for use in anintegrated power control system has a base including a housing anddefines a cavity within the housing for receiving a power switch. Thecontrol assembly includes a control module configured for generatingcontrol signals for controlling the power switch for selectivelyproviding power to a power load. A control housing is configured forhousing the control module and adapted to be releasably coupled to thebase housing and is configured for electrically coupling to controlcouplers on the base housing for providing the generated control signalsto the power switch within the housing cavity upon coupling the controlhousing to the base housing.

Referring to FIG. 19, the control unit 1800 as described above withregard to FIG. 18 is illustrated assembled with the cover 1814 attachedto the control housing 1802 and with a plurality of connectors 1816A,1816B, and 1816C positioned within the connector receiving cavities (notshown) and retained by the connector retainers 1820. The assembledcontrol unit 1800 is positioned for coupling to a base 1901 having ahousing 1902. The base housing 1902 includes a control unit cavity 1904adapted to receive the lower portion 1806 of the control housing 1802.One or more base fixtures 1908 are positioned and adapted for couplingto one or more of the flexible mating members 1804A for releasablycoupling the control unit 1800 to the base housing 1902. As noted above,the base housing 1902 and the control housing 1802 are adapted tomechanically and electrically couple the control unit to the variouscomponents of the base housing. Such coupling arrangements will bebetter understood by referring to FIGS. 20A and 20B.

As shown in FIG. 20A, the base housing 1902 includes a solid state relayor power switch cavity 2002 for receiving the SSR 1402. In thisembodiment, the base housing 1902 and the power switch cavity 2002 aredimensioned and adapted to completely receive the SSR 1402, and havesubstantially the same footprint as the SSR 1402. As noted above, theSSR 1402 is well known in the art to have a hockey puck configuration.The SSR 1402 includes screw seats 1404 for connecting to power andcontrol leads. Also, the SSR 1402 includes a thermal conducting base2004 and one or more connection fixtures 2006 for fixedly coupling theSSR 1402 and its thermal conducting base 2004 to a heat sink 1602. Thebase housing 1902 is configured to surround and encompass the SSR 1402while it is attached to the heat sink 1602. The base housing isconfigured to receive a variety of SSRs 1402 each having a differentheight from the electrical terminal to the thermal conducting base 2004while still ensuring appropriate contact by the thermal conducting base2004 with the heat sink 1602 and the required electrical connectivity tothe screw seats 1404. This can be accomplished by the power switchcavity 2002 and the base housing are dimensioned to have a standarddatum for electrical connectivity for the tallest height SSR 1402 whilealso providing for the SSR cavity depth to enable the shortest heightSSR 1402 to extend to contact the heat sink 1602.

Referring now to FIG. 20B, a top view of the base housing 1902illustrates details of the control cavity 1904 and the electricalfeatures and associated coupling provided by the base housing 1902. Apair of switch control terminals 2008 are positioned for coupling to thecontrol screw seats 1404 of an SSR switch 1402 received within the powerswitch cavity 2002. In this embodiment, a pair of screws 2009 arecoupled to the screw seats 1404. The pair of switch control terminals2008 can be configured to not only electrically and mechanically coupleto the screw seats 1404, but can be configured to fixedly couple thebase housing 1902 to the SSR 1402. As shown in FIG. 20A, each switchcontrol terminal 2008 can include a flexible or spring electricalcoupler 2024 configured to electrically couple to the control unitelectrical couplers 1824 and one or more housing coupling fixtures 2026configured to couple to a portion of the base housing 1904 when theswitch control terminal is fixed to the screw seat 1404 by a screw.

A pair of power terminals 2010A and 2010B are configured and positionedfor coupling to the power terminal screw seats 1404 of the SSR switch1402 by a pair of screws. The base housing 1902 includes a bus bar 2012for coupling power terminal 2010A to an external power terminal 2014. Aswill be discussed, the bus bar 2012 can be configured to not onlyprovide electrical connectively, but also provide for fixedly couplingthe base housing 1902 to the SSR 1402. A second bus bar 2016 couplingthe power terminal 2010B to a second external power terminal 2018. Thesecond bus bar 2016 can also be configured to fixedly couple the basehousing 1902 to the SSR 1402. The second bus bar 2016 can also include acurrent sensing portion 2020 and is configured and positioned forproviding a current for sensing by a current sensor associated with thecontrol unit 1800 when the control housing 1802 is positioned with thecontrol cavity 1904. A power terminal cover 2022 can provide forcovering the external power terminals 2014 and 2018 to provideadditional safety in the presence of unsafe power loads. As shown inFIG. 20A, the first and second external power terminals 2014 and 2018can include a coupling fixture for fixedly coupling to a wire orelectrical conductor. Additionally, the base housing 1902 can alsoinclude an external connection cavity 2028 configured about the externalpower terminals 2014 and 2018 for receiving on of the wire conductorscoupled to the power terminals 2014 and 2018.

In another aspect of the invention, a power control system includes abase having a housing for releasably receiving a control unit anddefining a first cavity for receiving a power switch, a second cavityfor receiving a definite purpose contactor, an input power terminal, anoutput power terminal coupled to receive switched power from an outputterminal a received power switch. The base also has control couplers forcoupling to an input and an output control terminal of the receivedpower switch and a plurality of electrical connections. A definitepurpose contactor is located within the second cavity and is coupled bya portion of the electrical connections in series with the input powerterminal, an input terminal of the power switch received within thefirst cavity, and the output power terminal. A control unit isconfigured for providing control signals to the definite purposecontactor and control signals to the received power switch forselectively providing, at least a portion of, the power received at theinput power terminal to the output power terminal. The control unit hasa housing adapted to be releasably coupled to the base housing. Thecontrol unit and base being configured to electrically couple thecontrol unit to the control terminals of the received power switch as afunction of the control unit being releasably coupled to the base. Thecontrol unit includes a limit component having a limit functioncharacteristic wherein the definite purpose contactor control signalsare a function of the limit function characteristic.

Referring now to FIGS. 21 and 22, a power control assembly 2100 similarto the power control assembly 1900 of FIGS. 19 and 20 is illustrated.However, the power control assembly 2100 includes a contactor within thebase housing as an added power switching function. A base housing 2102is configured to releasably couple to the same power control unit 1800within a control cavity 2103 and as generally described above to includekeying, coupling, and interoperability. However, in this arrangement,the power control unit 1800 and the base housing 2102 are configured toorient the power control housing 1800 at a ninety degree orientationwith regard to the received SSR 1402 and the power switch cavity withinthe base housing 2102. In some embodiments, the coupling between thecontrol housing 1802 and the base housing 2102 utilizes a different setof opposing flexible members 1804B (as compared to the flexible members1804A of FIG. 19). Additionally, in the power control assembly 2100 anintegrated heat sink 2104 and the base housing 2102 are configured tohave substantially the same footprints. Additionally, it should be notedthat a width of the base housing and the heat sink 2104 can bedimensioned to be substantially the same width of an SSR 1402 receivedwithin the power switch cavity of the base housing 2102. Additionally, amounting plate 2106 such as for screwing the power control assembly 2100to a mounting surface (not shown) can be attached to an underside of theheat sink 2104. In some configurations, the mounting plate 2106 can alsobe adapted for coupling to a DIN rail.

FIG. 22 provides an exploded perspective of the power control assembly2100. A grounding connector 2202 can be provided for coupling a groundto the heat sink 2104. The heat sink 2104 is configured to fixedlycouple to the SSR 1404 power switch and to thermally mate with thethermal surface 2004 of the SSR 1404. In this illustration, the SSR 1404is oriented across a width of the heat sink 2104. As such, the basehousing 2102 includes a power switch cavity 2204 (while not shown inFIG. 22, the power switch cavity is shown by arrow 2204) on theunderside of the base housing 2102 and across its width such that thecontrol and power screw seats 1404 of the SSR 1402 are oriented ninetydegrees from that of base housing 1902 as previously discussed. The basehousing 2102 includes similar switch control terminals 2008 that coupleto the SSR 1404 and to the base housing 2102 and that include spring orflexible connectors 2024 for electrically coupling to the electricalconnections 1824 of the control unit 1800.

However, the power control terminations differ in the power controlassembly 2100 since a second power switch cavity 2210 is configured toreceive a second power switch, such as contactor 2212. The second powerswitch cavity 2210 can be open at the top or bottom to receive thecontactor 2212. As illustrated, the second power switch cavity 2210 isopen at the top and includes a plurality of flexible latching members2214 configured to couple and engage an engagement portion 2216 of thecontactor 2212. The base housing 2102 includes a power receiving portion2218 that is aligned and configured for receiving wiring connectionsfrom a power supply to couple to power input terminals 2220 of thecontactor 2212. The power control assembly 2100 includes, at least one,bus bar 2222 configured on the output portion of the contactor 2212 fordirectly establishing one leg of an electrical connection with theoutput terminal 2014. A second bus bar 2224 is coupled to the otheroutput leg of the contactor 2212 for coupling the contactor to the inputpower terminal of the SSR 1402. An auxiliary tap 2226 can also beprovided on the output of the contactor 2212 to enable the tapping of aportion of the power switched by the contactor 2212 and providing thetapped power to another external power load or switch. The auxiliarytaps 2226 can be separate components or can be integrated into bus bars2222 and 2224 as shown.

A contactor control lead 2228 is provided to include a contactorcoupling fixture 2230 for coupling to a control terminal 2232 foroperating the contactor 2212. A flexible control unit coupler 2234 canalso be configured and positioned within the base housing 2102 forcompressively coupling with associated control leads of the control unit1800 upon the insertion of the control housing 1802 within the controlcavity 2103 of the base housing 2102. A power terminal cover 2022 can beused to cover the power terminals 2014 and 2018. Additionally, acontactor cover 2234 can be configured for covering the second switchcavity 2210 including the contactor 2212 received therein. Additionally,the contactor cover 2234 can include an integrated input power terminalcover 2236 for providing protection to the input power terminals 2220.Further, the contactor cover 2234 can include an auxiliary tap port 2238configured to allow access to the auxiliary taps 2226 without removingthe contactor cover 2234.

As such, the power control assembly 2100 is configured to provide afully integrated power control over both a SSR 1402 and a contactor2212, which can be connected in series. Additionally, the power controlunit 1800 can include control modules 1810 for controlling the SSR 1402via control terminals 2008 and a limit or contactor control module 1810for controlling the contactor 2212 via the contactor control coupler2234. In this embodiment, the power control assembly 2100 is fullyintegrated within a platform having a optimal footprint for operating aSSR 1402 and contactor 2212, while providing for the necessary heatdissipation. However, within the power control assembly 2100 no manualwiring connections are required once the SSR 1404 is coupled to the heatsink 2104 and the base housing 2102.

Similarly to noted above, the base housing 2102 and power switch cavity2204 are configured to receive a plurality of heights of SSR 1402.However, in this arrangement, the base housing 2102 also includes a basehousing pivot portion 2240 to enable the base housing 2102 to pivotduring secondary coupling by a coupler 2242 at the contactor end of thehousing 2102, e.g., the end away from the SSR 1402 and its coupling tothe heat sink 2104.

In one embodiment as illustrated in FIG. 22, the current sensor 1824 cansense a current being provided by the SSR 1402 to the output powerterminals 2014 and/or 2018. A limit control module that receives asensed limit characteristic associated with the power load 120 can alsocontrol the contactor 2212 as a function of the sensed current. This canprovide an additional safety feature to the power control assembly 2100since the SSR 1402 typically fails in a closed or conducting state. Theswitch control module that provides the controls signals to the SSR 1402can determine that its control state is an open mode and determine thatcurrent continues to be provided by the SSR 1402. As such, the switchcontrol module can determine that the SSR 1402 has failed and provide analarm or error signal or message. The limit or contactor control modulecan receive the SSR failure signal or message, and open the contactor toterminate input power from being provided to the SSR 1402 or from beingprovided to the power load 120. This interoperability is just onefeature and functionality that is enabled by the features and functionsobtained by the integrated power control assembly 2100.

In other embodiments of the invention and with reference to FIGS. 18-22,the invention includes a method of assembling a power control assemblyincluding inserting a solid state relay 1402 having a hockey puckconfiguration into a cavity 1904 or 2103 defined by a base havinghousing 1902 or 2102, coupling an input power terminal to an inputterminal of the solid state relay 1402, and coupling an output powerterminal to an output terminal of the solid state relay 1402. The methodalso includes coupling a first control attachment fixture 2008A to afirst control terminal 1404 of the solid state relay 1402, coupling asecond control attachment fixture 2008B to a second control terminal1404 of the solid state relay 1402, and inserting a control unit 1800having a control housing 1802 onto the base housing 1902 or 2102. Thecontrol housing 1802 and the base housing 1902 or 2102 are configuredfor releasably coupling the inserted control unit 1800 to the base suchthat inserting a control unit 1800 includes compressively coupling thecontrol unit 1800 to the first control attachment fixture 2008A and thesecond control attachment fixture 2008B and completing an electricalconnection between the control unit 1800 and each of the controlterminals 1404 of the solid state relay 1402.

Similar processes and steps of assembly of the power control assembly,according to various embodiment of the invention, such as power controlassembly 1900 and 2100 are described above and by FIGS. 18-22, as isknown to those skilled in the art of such assembly.

In some embodiments, the components and modules of a power controlassembly include various features, due at least in part, to the abovedescribed system integration and component processing functions. In yetother embodiments, the power control assembly includes a sensormultiplexer that can include a multiple channel switch to combinemultiple sensor inputs to a single analog/digital A/D channel. In onearrangement, a first multiplexer is coupled in parallel with a secondmultiplexer. These multiplexers receive control signals from independentchannel select circuits. The inputs of these multiplexers are used todetermine limiting actions of a limit component. Where two multiplexersare connected and controlled in this arrangement, the limiting componentdetermines if the channel selection circuits are performing correctly.If the channel selection circuits are performing correctly, theresulting input to the A/D channel will produce an OPEN sensorcondition. From this signaling, the limit control component can applythe limiting function.

As discussed, the integrated mechanical and electrical connectivity ofthe power control assembly and between components or modules within apower control assembly provides for improved connectivity by reducinguser interaction due in part to a reduction in the number of connectionsor connection points, and improving the reliability of the remainingconnections. The inter-component connectivity provides for improvedcommunication that enables internal system diagnostics, configurationmanagement, system and component administration, advanced functionality,mechanical alignment, and custom designs, as some examples.Additionally, the inclusion of component or module processing systemswithin components provides for higher level functionality with eachcomponent and within the unit or system. These include, among otherfeatures, data modeling, system modeling, and system configurationmanagement.

In another embodiment, connections or terminals for connection toexternal devices, such as sensors, can utilize a gang connection. A gangconnection provides for ganging of a plurality of devices with minimaluser involvement and within minimal space. In such arrangements, theganging of devices such as sensors onto common terminals or connectionpoints reduces the overall number of connection points and possiblepoints of failure.

In another embodiment, a customized or proprietary SSR configuration orconnection method can be utilized and configured within one or moreembodiments of the power control assembly. In embodiments of the SSRpower control assembly, one or more components can provide an electricalground or the ground can float. In the described SSR embodiments, thepower control assembly provides multi-component coupling undercontinuous compression such that per-module or per-component userinteraction or input is not required with regard to the variousconnections there between.

In another embodiment, the combination of the power switch and limitcontactor can be arranged so that the limit switch and power switch arecombined in a parallel circuit to the power load. In such an embodiment,the power switch acts as a primary load switch during the connection ordisconnection of the power supply to the power load. This embodiment canprovide a no-arc feature. This embodiment includes the same attributesof reduced wiring and wiring mistakes in addition to the benefit of noarcing.

Components and modules of the power control assembly can include one ormore devices such as a circuit or processing system that requires devicepowering. In such cases, device powering for internal system operationscan be obtained parasitically from the supply power received from thepower supply, can be received from a dedicated power supply input, orcan be powered from the communication link such as a WatBus™. In manyembodiments, these device power requirements are often very low andrequire very low currents. In another embodiment, the same low currentfor operating or actuating the power switch relay to drive the highcurrent contactor can be used for device powering.

In some embodiments, one or more of these internal and externalconnections can include a sensor, monitoring, or feedback mechanism toprovide the power control assembly or system, a remote monitoringsystem, or an operator of the assembly with feedback relative toconnection integrity pursuant to a predetermined standard orcharacteristic such as torque. One or more connection characteristicscan be identified and one or more operational operations such as analarm indication can be initiated in response to the connectioncharacteristic. In another embodiment, system or component diagnosticoperations or processes utilize one or more of the characteristic toprovide intra-power control assembly connection diagnostics for troubleshooting, trouble isolation, configuration management, and maintenance.

One or more components have operational or communication interfaces forcommunicating with other components within the power control assemblyand system. Each component can have a plurality of versions or modelshaving different combinations of features, functions and modules.However, within the power control assembly, each model or version ofeach component will connect with and operably couple to any and allmodels and version of any other component. As such, each version ormodel of each component can be utilized in the power control assemblyand combined in a flexible manner to address the requirements of a userapplication for the power control assembly. Additionally, all or fewerof the components within the power control assembly can be both backwardand forward compatible in conjunction with the inter-componentconnectivity and component self-identification.

In some embodiments, the power control assembly as described herein willenable a user to easily identify individual components and moduleswithin the power control assembly.

In another embodiment, the integrated combined power control assemblyincludes an integrated thermal heat transfer management. Each componentof the power control assembly includes a heat transfer assembly, thatwhen assembled with other components conducts heat to one or more heatsinks. In one embodiment, a unit can utilize the power switch componentas a unit heat sink, as the power switch component can include anintegrated heat sink or configuration in conjunction with a mounting ofthe power switch component. In another embodiment, one or morecomponents of the unit can include or be comprised of a thermallydirectional material that can act as a unit or component heat sink. Sucha material can thermally operate similar to a diode's electricaloperation by blocking the transfer of heat in one direction and allowingheat to transfer in another direction. In one embodiment, thethermally-directional material can act like a funnel and transfer heatfrom a component within the unit to a component having a larger surfacewith superior heat transfer thereby improving heat transfer andminimizing heat build-up within the unit overall.

In some embodiments, the inter-component and/or inter-module connectionswithin the power control assembly include integrated ElectromagneticForce (EMF), Electromagnetic Interference (EMI), and thermal shieldingfor each of the components and the power control assembly as a whole. Inone such embodiment, a power control assembly housing or cover can beintegrated into each component such that when combined an integratedhousing provides one or more of these shielding functions. Additionally,the housing can also inhibit operator interference or contact withwiring, connections, or critical components. In one embodiment, thehousing or means for engaging an interconnecting wire to the unit orcomponent can inhibit the physical movement of the wire lead thatbecomes disengaged from a connector of the power control assembly or acomponent thereof.

For example, in some embodiments of the integrated power controlassembly, one or more housings provide for the mechanical and electricalconnectivity of the various components. Such housings can be comprisedof a molded or machined material such as plastic, by way of example,that provides the relationship between the geometries of the powerswitch (shown as an SSR or contactor), the control, and the limitcomponents and include air duct geometry suitable for convection airflow. These combined housings, when assembled, can provide an air ductthat will channel air flow vertically over the top surface of the powerswitch component. The air flow originates from inlets located verticallybelow the power switch heat generation point. This air flow is furtherentrained vertically through the power control assembly via air flow ribgeometry formed within the plastic part geometry. The orientation of theribbing and corresponding inlet and outlet vent openings promote anincrease in air flow velocity due to the greater volumetric expanse inthe duct area directly (vertically) above the power switch heatproducing area. The natural convection is enhanced by the componentgeometries and promotes an increase in air speed as the air passes fromthe constricted area at the power switch upward to an ever increasingopen area (the rib area) to the outlet vent points. The plasticembodiments and the adjacent power switch module provide the ductgeometry necessary to enable this thermal management mechanism. Thisparticular embodiment enables improved power switch cooling as comparedto conventional assemblies.

In one embodiment, the power switch component can be a contactor modulehaving an integrated integral line voltage and/or load current sensingmodule and functionality. In another embodiment, the power switchcomponent can include an integrated limit switch module. In one or moreembodiments, the power switch or contactor component provides forselectively providing power from a power supply to a power load. Thecontactor component with the limit module would also provide a limitswitching function as a function of a predefined threshold limit. Such alimit module can include a temperature sensing function or can be avoltage or current sensor. As just one example, the limit module canutilize a current monitor including a current transformer, Hall Effectsensor or GMS device—non-circuit breaker style, as are known in theindustry.

Some embodiments include one or more sensor interfaces for communicatingwith an external sensor sensing an external operation associated withthe user application or operation. In another embodiment, the sensor canbe integrated, at least in part, into the power control assembly. Insome cases, the sensor can provide or the power control assembly candetermine the type of sensor interfacing with the power controlassembly. In such a case, the power control assembly can adjust orreconfigure one or more operating parameters, a profile, or aconfiguration as a function of the sensor type. As just one example, thepower control assembly can determine the type of sensor and optimize afunction or interface to one or more temperature scales or ranges inorder to optimize the performance of the temperature measuring functionor the power control function associated with the temperature measuringinput.

Each component of the power control assembly provides interconnectingcomponents with component data for self-identification such that theinterconnecting components are provided component identification datarelated to all interconnecting components. Such component data can becommunicated via the communication link, via a proximity switch orrecognition device, or via another interface including a user inputinterface.

The component data can include the type of component, the model number,manufacturer, software version, features, functions, serial number,profile, configuration data, component module data, customer applicationdata. Additionally, one or more components of the power control assemblycan provide component data and data associated with itself and allinterconnected components to a third component thereby providing for thedissemination of component data throughout the components of the powercontrol assembly. As such, each component detects and identifies everyother component within the power control assembly. Such information canbe stored in a memory of each component and can be used to update aprofile or configuration of the power control assembly. Additionally,previous or predetermined component data, configuration data, or systemprofiles can also be stored for comparison, for reference, forselection, or as a default.

In some embodiments, the power control assembly and/or system includes aself-identification capability and its integrated functionality. Asillustrated in FIGS. 23 and 24, a power control assembly 2300 having aCPU 2302 is operably connected to input/output modules 2304A-C havingconnectivity gates 2306A-C that are associated with a plurality ofcomponents comprising the power control assembly 2300. Prior to power-upof the power control assembly, each of the connectivity gates 2306 inthe components are open. Upon power-up, the power control 2302broadcasts a message over the communication bus 507 to each of the I/Omodules 2304. One such message can be a “next mode” message. The firstphysically connected I/O module 2304A receives the message and extractsits node address from the message. In response, I/O module 2304A closesits associated gate 2306A thereby connecting a second module 2304B tothe communication bus 507 and to the control 2302. The I/O module 2304Asends an “identified message” in response to the next mode message tothe control 2302. The I/O modules 2304A can then close itself fromfuture broadcasts. Each of the operations is repeated until all gates2306 are closed and no response is received by the control 2302, therebyindicating no further components 2304 are connected to the communicationbus 507.

A power control assembly or components having component data for each ofthe components within the power control assembly can access the data anddetermine an operational or diagnostic operation in response. This caninclude providing feedback, initiating instructions, initiatingdiagnostics, initiating maintenance, initiating an alarm or a messageconsistent with best practices, optimal profiles, or preferredconfiguration or setup.

The integrated power control assembly according to some embodiments ofthe invention can generate an input/output configuration list duringpower control assembly initialization. An input/output header can begenerated and I/O data obtained for a first component in table 1 and fora second component in table 2. FIG. 25 illustrates some embodiments ofsuch an input/output data table 2500. As shown, the component data table2502 includes a data address for each component on the communication bus507. Additional data items can include an identification of the numberof associated devices having inputs and outputs, the input attributes,and the output attributes, by way of example. For each output 2504A-Nand each input 2506A-N, an attribute can include a type, a list ofsupported types, data, and data units for each input. These can beassociated with an initial or default value or be associated with aparticular user application.

In this manner, upon receipt of the interconnected component data, acomponent can analyze its operations and the operations of the powercontrol assembly to ensure that effective and efficient operations andinterfaces are provided by the combination of components comprising thepower control assembly. Additionally, the component can activate ordeactivate features and functions consistent with the capabilities ofthe interconnected components or the power control assembly as a whole.In this manner, the power control assembly can reconfigure to maximizethe functionality of the power control assembly based on thecapabilities of each and every component. One or more components canadjust a parameter, operation, or interface as a function of thereceived interconnected component data.

Additionally, utilizing the communications bus 507 and interfaces, twointerconnected components can negotiate with each other in establishingan optimized or predetermined interconnection. Such negotiations can bea function of algorithms, tables, or decision flows or diagrams.

As all component data can be available to each and every componentwithin the power control assembly, each component and the power controlassembly or power control system (having multiple power controlassemblies) as a whole can self-configure as a function of the availablecomponent data. Such self-configuration can be initiated at initialsystem setup, upon installation of an additional or replacementcomponent, upon occurrence of an event such as an error, or reboot, oras a function of receiving a re-configuration input from a user or aremote system. For example, a second component can be replaced by asecond component of a later version having additional functionality. Assuch, upon insertion of the replacement second component, the othercomponents within the power control assembly can recognize that thereplacement second component has the new capabilities and as a resultactivate dormant capabilities within their own components.

Additionally, as each component within the power control assembly canhave knowledge of interconnected components, the component can includeoperational data related to those interconnected components such that itcan determine, estimate, or infer the status or activity occurring inthe interconnected components or within the power control assembly as awhole, without actually receiving an indication or message. By utilizingthe component data, one or more components can produce high leveldiagnostic, analysis, parameters, and characteristics thereby providingfor improved high level control of system level diagnostics andoperations.

In one exemplary embodiment of self-recognition, a physical proximity ofone component to another component within the power control assembly orsystem can self-enable features and functionality. By way of example, aphysical proximity switch can be a magnetic switch. For example, a firstcomponent can include a magnetically operated switch positioned torecognize a magnet associated with a second component such that when thefirst and second components are combined in a power control assembly, acircuit in the first component is completed thereby providing for aproximity indication in the first component that the second component iscoupled thereto. When such a proximity indication is present, one ormore features in the first module can be enabled or disabled.

As one example of such an embodiment, a limit controller within thepower control assembly can have set a limit responsive to a particularheater type being controlled. In response, the controller within thepower control assembly sets a high setpoint limit. As another example ofone embodiment, a PID controller adjusts for a change between a setpointand a limit setting such as to minimize or eliminate an overshoot thatwould produce or result in a limiting action.

In yet another embodiment, when the power control assembly, system or acomponent cannot self-configure or has an error, a component can utilizethe stored data to one or more components having the stored componentdata for reconfiguration. In such a case, one or more components canaccess one or more default or prior configurations, information orprofiles, to provide a recovery of the component by replacing thecurrent configuration, information or profile with a default or previousprofile or configuration.

In another embodiment, the power control assembly can identify the typeof heater or operation of the heater and recommend or determine apreferred or desired startup or operational feature to an operator oranother components, system or power control assembly, such asrecommending a soft start or slower ramp rate or to initiate anotheroperation such as a bake out. As another example, a temperature range orpower level can be determined as a function of a sensor type to providefor improved control.

In another embodiment, the power control assembly can automaticallyreconfigure to optimize performance to sensor type or operation or to aparticular temperature scale or range for a sensor or sensor type. Asone such example, a power control assembly can have a plurality ofsensors associated with it. In one arrangement, the plurality of sensorscan include different sensor types such as a Type K sensor and a Type Esensor. The Type K sensor and the Type E sensor can be arranged inparallel. For controlling one or more operations of the power controlassembly or components thereof, the system can utilize the signals fromthe Type K sensor over the full operating range, but utilize the signalsfrom the Type E sensor over a controlled range to provide improvedtemperature identification and resolution.

As an example in a heater element load application, a thermocouple canbe utilized to control temperature. However, the power control assemblycan utilize or switch to another sensor or sensor type to improve systemmeasurement at critical control points or ranges. For example, at acritical point in the operation or control by the power controlassembly, the system can utilize a pressure or flow sensor rather thanthe temperature sensor.

In another example, the power control assembly can include a pluralityof sensors and sensor types. A transition between one sensor type toanother sensor type can be controlled using a control method, by way ofexample, a proportional allocation method or algorithm, so as to manage,reduce, mitigate or smooth over sensor and switch disturbances. Forexample, the switch over from 100 percent from sensor A to 100 fromsensor B would be ramped or variably controlled through ranges from 0 to100 percent at various incremental amounts.

In yet another embodiment, a control component is configured to monitoran independent temperature sensor and a limit component is configured tomonitor a second independent temperature sensor. The limit componentcompares temperature information of its sensor with that of the controlcomponent's sensor. If the difference is determined to vary more than apredetermined amount, the Limit component initiates an action such as acorrective or notification action. This embodiment provides a redundantmethod of insuring the thermal system remains in a safe temperaturecondition.

In another embodiment, a component within the power control assembly caninclude a wiring auto-correction capability. The component can have oneor more wiring connections that are wired during installation by a user.However, some wiring connections can require a particular wiring orderor polarity. In such a case, the component can test or sense the wiredconnection and identify that one or more of the wiring terminations areincorrect. The component or system can provide an indication to the usersuch as a light or message. In other embodiments, the component canreconfigure the interface or internal connections or logic path such asto swap, exchange, or reverse the mis-wired connections without userinvolvement. As one example, a sensor can have polarized leads. When thesensor leads are connected on a connection terminal of the power controlassembly or component, the component can sensor the incorrect polarityand swap the leads automatically to correct the mis-wiring and toprovide for continued operation without user involvement.

As discussed, each component of the power assembly or power controlsystem can include a processor, memory, and/or communication interface.In some embodiments, one component can not only monitor or identify anoccurrence within its own operation, but also have knowledge of presentand past occurrence of one or more other components comprising the powercontrol assembly. These can include occurrences of diagnostic parameterssuch as a change of a state, a change of a mode, a change of a status, afailure, a change of a field parameter, a change of the field operatingcharacteristic, a value of a field parameter crossing a threshold, analarm, an alert, and a value of the field operating characteristiccrossing a threshold.

As such, a component of the power control assembly can include one ormore system or component diagnostic modules for diagnosis of anoperation or status of the system or component. In one exemplaryembodiment, the diagnostic can include a parameter associated with acalibration, a profile, a configuration, a system administration, and asystem operation.

The diagnostic module can include an algorithm, a program, an artificialintelligence module, a modeling module, a mapping, a graphical analysis,a rule, a comparator, and a look-up table, by way of example, fordiagnosing the system or component. In one such embodiment, thediagnostic module can include a neural network, an empirical data, anumerical data, a fuzzy logic circuit, a neural fuzzy circuit, apolynomial algorithm, a residual life algorithm, an artificialintelligence module, a modeling module, and a statistical function.

In another embodiment, the power control assembly or component cansimilarly provide other internal functions including a trouble shootingmethod, a fault detection, a fault isolation, a root cause, a setting, alimit, a threshold, a calibration, a failure prediction, a maintenanceprocedure, a validation, a verification, a traceability, anauto-configuration, an architecture alignment, a fingerprint, anidentification, a theoretical modeling, a self-administration, and aself-tuning rule.

As another example of some embodiments of a power control assemblydiagnostics, the control assembly can include one or more temperaturemeasurements for measuring the heat transfer from the power switch tothe associated heat sink, the temperature of a wired connection, or thetemperature of an interface.

In another embodiment, the power control assembly or one or morecomponents thereof can reconfigure an interface, parameter, or processon a temporary basis to place modules, components or power controlassemblies in a test or diagnostic arrangement. For instance, one ormore components can be placed in series to isolate a trouble through aprocess of elimination. As one example, in a power control assemblyembodiment, a fuse, power switch, limit switch, and protection devicecan be placed in series with the source voltage and the interconnectionpoints between each of the components tested to identify which componentfailed.

One embodiment of the power control assembly provides for a connectionor assembly of components that includes a signal or indication that theassembly was correctly and completely assembled and that all requiredterminations and connections have been made and are suitable foroperation. The indication can be an electrical signal, a message, a beepor audible indication, a light, or a flag.

In some embodiments, the power control assembly can include initial andongoing power loop system verification, for example, verification of thethermal loop when powering a heating element.

After components of the power control assembly and/or its components areassembled, the power control assembly can automatically or upon userinitiation, self-verify component coupling and proper functionalityprior to activation of application power or providing of power to apower load. For example, when a power control assembly is firstassembled, each of the components self-verifies proper internaloperations and configurations and also verifies proper connection andcharacterization alignment with the other components such that thecombination of components provides the required system level profile andcharacterization. Each component, the power control assembly, or thepower control system can also verify that each and every connection,including the power supply and power load connections, are secure andwithin predefined specifications. After these verifications arecomplete, the limit module and/or the power switch are authorized orenabled to initiate a powering mode for providing supply power to apower load served by the power control assembly or loads served by thepower control assembly. Such verifications can be at systeminstallation, system powering, at other pre-determined events and times,when an alarm or error occurs, at regular intervals or continuously, byway of example. Additionally, in some embodiments the power controlassembly can include an indicator such as a flag or light or signal suchas a green light to indicate proper connectivity and installation and/ora flashing green light to indicate proper polarity has been achieved ifrequired in a particular connection.

Additionally, when a verification results in the identification of averification issue, the power control assembly, a component thereof or apower control or operational system can initiate a component level orsystem level diagnostic or maintenance routine to determine the sourcevia self-initiated trouble shooting. In some embodiments, the assemblycan also reconfigure to eliminate or isolate the problem when possible.

As an example of one embodiment, the power control assembly can verifythat all power connections are secure to ensure proper connection. Thecontrol can compare the recent reading with a previous reading andidentify a degradation of the connection as might be indicated by anincrease in the temperature, an increase in the voltage differentialacross the connection, or detect an increase in the deflection or strainof a power supply line or power load line. When a problem is identified,the system can diagnose the potential power lead failure prior tofailure and initiate a preventive maintenance action or routine or canprovide an alarm, indication, or message to prevent a failure thatcauses an out of service condition.

In some embodiments, the power control assembly can utilize theintegrated nature of the power control assembly to provide new and novelpower control functions and functionality. As one example, a powercontrol assembly of the power control system can provide a new limitingfunction not previously provided by temperature-only power limitingdevices. By leveraging the integrated nature of the power controlcomponents within the power control assembly, power control operatingcharacteristics or operating events in addition to temperature can besensed or identified. The limiting function of the limit module can bebased at least in part on one or more of these power control operatingcharacteristics and/or operating events.

The temperature sensor associated with the limit module can be anysensor configured to sense a temperature, including a thermocouple, aresistance temperature detector (RTD), a diode, a semiconductor sensor,a resonance temperature sensor, an infrared sensor, a thermistor, and atransistor.

The power control assembly can also include sensors to measure othercharacteristics or to identify the occurrence of an event, including apressure sensor, a flow sensor, a stress sensor, a motion sensor, aposition sensor, a voltage sensor, a current sensor, a Hall effectsensor, a magnetic intensity sensor, a gas sensor, and a chemicalproperty sensor.

The power control operating characteristic can include a resistance, acurrent, a voltage, a Hall effect voltage, an energy, a mass, a powerincluding an electrical power, a capacitance, an inductance, areluctance, a phase, a timing, a frequency, a time, a mode, a status, afailure, a position, an alert, an alarm, a state, a magnetic intensity,data, and a parameter.

The power control assembly or system operating event can include achange of a state, a change of a mode, a change of a status, a failure,a change of a field parameter, a change of the field operatingcharacteristic, a value of a field parameter exceeding a threshold, analarm, an alert, and a value of the field operating characteristicexceeding a threshold.

Additionally, by utilizing the communication bus 507 of the powercontrol assembly, the limit function can receive an operatingcharacteristic or event occurrence indication from a field device thatis external to the power control assembly but that can be associatedwith the user application of the power control assembly. Thecommunication can be received, either directly or indirectly from anactuator, an accelerometer, a valve positioner, a gauge including apressure gauge, a solenoid, a power supply, a heater, a valve includinga solenoid valve, a meter, a motor, a pump, a switch including a thermalswitch, a fusible link, and a memory device. Additionally, thecommunication can be received from a fabrication system, a manufacturingsystem, an assembly system, a processing system, an operational controlsystem, an asset management system, a maintenance system including apredictive maintenance system, and a supervisory control and dataacquisition (SCADA) system. In such embodiment, the limit function may,at least in part, be a function of the received communication.

As with temperature-based limit system, one or more of thesecharacteristics, parameters, or events can be combined in a table,algorithm, or other determination to ensure power control assemblyintegrity, application operational integrity, as well as providingimproved efficiency and safety.

In one embodiment, the limit function provides an operating limit to thesupply power through inter-module connectivity and communication. Whenan operating characteristic or operating event indicates a limitoccurrence, state, or status, the limit on providing power to the powerload remains disengaged, thereby preventing operation of providing powerto the power load. The system monitors the power control assembly andonly disengages the limit function when a no limit situation is present.This can be when all power control assembly components and power controlsystem units or assemblies are operationally ready, or when apredetermined limiting situation is cleared.

The power control assembly can as sense data and provide feedback forcomparison of actual to expected values. In such a case, the assembly ora control components associated with the assembly can determine thedifference and take an appropriate or determined action as a function ofthe determined difference. This can include the determination that amaterial buildup is occurring on the limit sensor or the control sensorwhich can impair the ability of the sensor.

In some embodiments, a component or operation of a component or systemcan also utilize the component status data and information for improvingone or more operations. For example, if a limiting action occurs in thelimit component during a control function of the controller such as aPID, the controller component can suspend the integral windup conditionor another operation until the limiting action in the limit componentterminates. In such a manner, the status of one component within a powercontrol assembly can improve an operation within another component,thereby improving the overall performance or operations of the entirepower control assembly.

These operations can include locking out or preventing an operation ofor by one component or sub-component or modules as a function of anoccurrence, a status, an alarm, an operation, a process, an error, acurrent, or a voltage, by way of example. In one application of this,the controller can lock out a defrost mode or operation during a controlcomponent being in the middle of an operating procedure.

In yet other embodiments, a user application can require that the powercontrol assembly provide power to a plurality of associated power loads.In such a case, a plurality of power control assemblies can be arrangedin a power control system to have a corresponding relationships with theplurality of power loads. The power control assembly can be configuredto ensure that each and every power control load operates in apredetermined manner. The power control system interoperates with theplurality of power control assemblies to monitor the power control loadsto ensure that user application requirements are met.

As one example of an embodiment, a plurality of power control assembliesof a power control system can be configured to provide power to a seriesor group of heating elements in a user thermal application. The userapplication can require that the heating of the application beconsistent and even whereby no hot spots are present. However, eachheating element can have a different heat transfer property due to theage of the heating element or the mounting arrangement. However, asensor associated with each power control assembly can monitor thethermal heat generated by each heating element and provide thetemperature data to the power control system. The power control systemcan determine that the power to one or more heating elements can needadjustment up or down to ensure a uniform and consistent heatingapplication.

In another embodiment, the user application can have a staged loading tominimize peak power and loading as a function of an efficiency oroptimization determination. In such an embodiment, the power controlassembly can include a program or algorithm such as to appropriate stagethe powering of the power load devices.

In one embodiment, two components or modules thereof of the powercontrol assembly can be configured to share resources in definedconfigurations or situations to provide for enhanced features andfunctionality and reliability of the system. For example, in oneembodiment of a power control assembly within a power control system,the unit can include a limit sensor and a control sensor. The system candetermine during operation that the control sensor has failed or is notfunctioning properly. In such an embodiment, the system can disconnector ignore the control sensor output and utilize the limit sensor as acontrol sensor. As another example, the power sensor can be utilized asa control input during manual power when the control sensor fails. Insuch embodiments, the power control assembly or a unit or componentthereof can continue to operate and provide power control functionalityeven when an otherwise essential element within the power control loophas failed. The system can also provide an indication, an alarm, or amessage indicating the failure and the failure mode operation.

In another embodiment, power control assembly can include a plurality ofpower control assemblies. In some embodiments, the plurality of powercontrol assemblies can have a common control module, e.g., one powercontrol module providing control functions to each of the plurality ofpower control assemblies. In such cases, the common power control moduleprovides for interoperability and management of the power controlassemblies comprising the power control system. This can include unit tounit communications and communication management, profile sharing,configuration sharing, storage of one or more profiles, configurations,characteristics, and/or parameters. This can also include an applicationprofile or a user profile. The controller can also enable unit to unitconfiguration management and system configuration management.

In some embodiments, the plurality of power control assemblies can havea common user interface, e.g., one user interface providing user inputand feedback for controlling each of the plurality of power controlassemblies.

In some embodiments, one or more of the plurality of power controlassemblies can be associated with a different and/or related portion ofa user application. Additionally, a plurality of power controlassemblies can be associated with a plurality of user applications, someof which can be associated user applications.

By way of example, a first power control assembly provides power controlto a first zone, a second power control assembly provides power controlto a second zone, and a third power control assembly provides powercontrol to a third zone. One or more of the zones can be associated orhave a relationship within the user application.

A user application profile or configuration is defined to include one ormore power control assembly profiles and configurations. The userapplication profile defines a user application profile; however, one ormore of the power control assembly profiles can be configurable duringoperation as determined to ensure that the user application profile iscontinuously met. Each of the power control assemblies monitors not onlytheir own internal power control assembly modules and interfaces, butcan also monitor one or more functions, modules, or interfacesassociated with one or more of the other power control assembliescomprising the user application and included in the user applicationprofile. By utilizing information associated with the user applicationprofile, a first power control assembly can be associated with a firstprocess that is experiencing delays or other problems. In such a case,one or both of second and third assemblies can self-reconfigure anoperation, their profile, or their configuration in response to thefirst power control assembly operations such as to ensure that theoverall profile or configuration of one or more user applications isachieved and that the relationship between the zones is addressed.

In one exemplary embodiment, the operation of one power control assemblyis adjusted as a function of the relationship between the zones orassociated user applications of the plurality of power controlassemblies. Knowledge regarding the relationship provides for detectionof deviations in other zones or power control assemblies, and adjustmentto one power control assembly can be responsive to deviations of one ormore other power control assemblies or user applications (such as azone) associated with another power control assembly.

Such power control assembly adjustments or reconfiguration can be madewithout direct sensing or monitoring of one or more parameters orcharacteristics of another power control assembly. This can include afailure in the user application and not necessarily the associated powerload device or the associated power control assembly.

As discussed above, one or more aspects and features of the inventionprovide for improvements in the operation and capabilities of a powercontrol switch. Some embodiments of the invention include monitoring aheat transfer characteristic or electrical characteristic of theinterface between components of the power control assembly and between acomponent of the power control assembly and an external applicationcomponent. In one such embodiment, a junction temperature of a solidstate device such as a power switch module or component is measured toensure proper performance within operating specifications andperformances. In other embodiments, the temperature of the heat sink canprovide a relative temperature that can be indicative of the temperatureof the solid state device and the heat sink junction. The measurement ofthe temperature of the solid state device is determined as a function ofthe temperature of the heat sink based on intrinsic data, a look-uptable, a matching, or an algorithm, by way of example. Additionally, thethermal bonding of the solid state device to the heat sink can bemodeled or determined as a difference. If the difference is larger thana predetermined value, this indicates a breakdown in the thermal bondingand therefore a potential source of failure.

In another embodiment, the control assembly includes a temperaturemonitoring sensor for monitoring the temperature of the junction betweenthe power switch (such as an SCR or SSR) and the heat sink associatedwith the power switch. In such an embodiment, a sensor can be positionedto directly measure a characteristic of the heat sink junction or acomponent of the junction (such as the backplate of the power switch orSSR) or a surface or body of the heat sink. While the characteristic ofthe heat sink junction can be temperature, it can also be acharacteristic that varies as a function of the heat transfercharacteristics. This can include a resistance, a voltage, or a current.

In an alternative embodiment, the temperature of the heat sink junctionsensor is indirectly measured by sensing a characteristic or temperatureof a component that can be indicative of the temperature of the heatsink junction. By way of example, a sensor can sense a temperature ofthe heat sink relative to the temperature of the junction temperature.In such a case, the system can estimate the temperature of the junctionbetween the SSR and the heat sink based on a model, an algorithm, and alook-up table or otherwise.

By determining the temperature of the heat sink junction, the powercontrol assembly can identify a potential or pending failure of thepower switch due to a breakdown in the thermal bonding or junctionbetween the power switch and the heat sink. For example, theidentification of a breakdown in the thermal bonding of an SSR toassociated heat sink can be determined when a measured characteristicsuch as temperature is greater than a predetermined threshold.

In another embodiment, the control assembly can include an electricalmonitoring apparatus or sensor monitoring an electrical characteristicof the interface between the power switch and a ground plane. Such anelectrical monitoring can provide a characteristic that is indicative ofa failure or pending failure of one or more components of the powercontrol assembly. In other embodiments, an electrical connection to theheat sink and an electrical connection to another system component canbe provided as a reference for a digital common, analog common, oranother point. The module or component can receive electrical signals ormeasurements from these connections and determines the voltage betweenthe connection points. The control module can then compare them to apredetermined value that can be zero, to determine an amount of leakagecurrent to ground. This determination enables the self-identification bythe component of a failure that results in a leakage current to ground.

For example, the power control assembly can include a failure indicationmodule that has at least one electrical kiss-off with one or more otherpower system components. The kiss-off can be a contact that iscompressed between two components of the system or can include aconductive spring protrusion that is biased towards a first componentwhen the second component with the spring protrusion being pressedagainst a conducting element of the first component. The componentproviding the electrical kiss-off can be any component within the powercontrol assembly including the controller or monitoring module. Thefirst component that is being kissed can be any component of the controlassembly and in some embodiments the kissed component can be a heatsink. In some embodiments, the kissing sensor can include an electricalconnection such as to sense a voltage of the ground reference. Theground reference voltage can be indicative of a leakage current througha faulty power load such as a heater element or an electric motor. Thesensed electrical characteristic can also be indicative of a breakdownor impairment of another component of the power control assembly. By wayof example, this can include an indication of a grounded sensor such asa thermocouple.

As discussed, one or more components of power control assembly caninclude an operating environment that can include a processing systemthat includes at least one microprocessor and a memory. These elementsare typically interconnected by at least one bus structure. Theprocessor can be of familiar design and include an arithmetic logic unit(ALU) for performing computations, a collection of registers fortemporary storage of data and instructions, and a control unit forcontrolling operation of the system. Any of a variety of processors,including at least those from Digital Equipment, Sun, MIPS, AnalogDevices, Silicon Laboratories, NEC, Intel, Texas Instruments, Cyrix,AMD, HP, and Nexgen, is equally preferred for the processor. Embodimentsof the invention can operate on an operating system designed to beportable to any of these processing platforms or can be proprietary toone or more processing platforms.

The memory can generally include high-speed main memory in the form of amedium such as random access memory (RAM) and read only memory (ROM)semiconductor devices. Other memory or data storage can also be includedin some components including secondary storage in the form of long termstorage mediums such as floppy disks, hard disks, tape, CD-ROM, flashmemory and other devices that store data using electrical, magnetic,optical or other recording media. The memory of the user interface canalso include display memory for displaying images through a displaydevice or interface. Those skilled in the art will recognize that thememory can comprise a variety of alternative components having a varietyof storage capacities.

The user interface component can comprise, by way of example, akeyboard, a button, a switch, a thumbwheel, a touchpad, a mouse, aphysical transducer (e.g. a microphone), biometrics measuring devices,bar code scanner, or an interface associated with any one of these userinput devices. Additionally, user interface device can also include aninterface for receiving data such a communication network interfaceutilizing a hard wire connection or a wireless connection.

As is familiar to those skilled in the art, one of the componentprocessing systems can further include an operating system and at leastone application program. The application program can perform one or moreof the monitoring, determining, or controlling functions describedabove. The operating system is the set of software which controls theprocessing system's operation and the allocation of resources. Theapplication program is the set of software that performs one or more ofthe task or features described or enabled above, by using processingsystem resources made available through the operating system. Both aretypically resident in the described memory.

In accordance with the practices of persons skilled in the art ofcomputer programming, embodiments of the power control assembly orcomponents thereof described above with reference to symbolicrepresentations of operations can be performed by the processing system.Such operations are sometimes referred to as being computer-executed orcomputer executable instructions. It will be appreciated that theoperations which are symbolically represented include the manipulationby the processing system of electrical signals representing data bitsand the maintenance of data bits at memory locations in the memorysystem, as well as other processing of signals. The memory locationswhere data bits are maintained are physical locations that haveparticular electrical, magnetic, or optical properties corresponding tothe data bits. Embodiments of the invention can be implemented in aprogram or programs, comprising a series of instructions stored on acomputer-readable medium. The computer-readable medium can be any of thedevices, or a combination of the devices, described above in connectionwith the memory system.

Although several power control assemblies and components and methods ofoperation have been illustrated in particular embodiments as the hockeypuck configured solid state relay (SSR), such an illustration has onlybeen shown by way of example, and is not intended to be limited to suchembodiments. Other systems and methods consistent with the variousaspects and embodiments of the invention are also contemplated withinthe context and aspects of the invention.

One or more embodiments of the power control assembly described hereinprovide for the reduced number of wire terminations that reduce thenumber of wire connections, reduce the potential for wiring errors,reduce the number of points of potential failure, and reduce laborrequired for installation and maintenance of the power control systemand its components.

Additionally, the integrated nature of some embodiments also providesfor the reduction in the number of components required for one or morepower control applications.

In some embodiments, these reductions can provide for improvedreliability, improved ease of installation, reduced installation costs,reduced maintenance requirements and cost, improved ease of component orsystem replacements and upgrades.

Additionally, some embodiments of the power control assembly provide forimproved granularity and scalability for power control systeminstallations. Such improved granularity and scalability will provideusers with reduced costs for power control applications.

When introducing aspects of the invention or embodiments thereof, thearticles “a”, “an”, “the”, and “said” are intended to mean that thereare one or more of the elements. The terms “comprising”, “including”,and “having” are intended to be inclusive and mean that there can beadditional elements other than the listed elements.

In view of the above, it will be seen that several advantages areachieved and other advantageous results attained. As various changescould be made in the above exemplary constructions and methods withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

It is further to be understood that the processes or method stepsdescribed herein are not to be construed as necessarily requiring theirperformance in the particular order discussed or illustrated, unlessotherwise noted. It is also to be understood that additional oralternative processes or method steps can be employed and still bewithin the scope of the invention.

1. A power control system comprises: an integration coupling mechanismfor mechanical and electrical coupling of a plurality of power controlsystem components; a communication link configured for providing acommunication among a plurality of power control system componentsutilizing the coupling mechanism; a power switch component adapted forcoupling by the unit integration coupling mechanism, the power switchcomponent selectively providing electrical energy to a load, said powerswitch component including a power supply interface for receiving powerfrom a power supply, a power load interface for providing, at least aportion, of the received supply power to the power load, and a powerswitch communication interface configured to communicate over thecommunication link, said power switch component adapted to the couplingmechanism for mechanical, electrical and communication coupling; and apower controller component for controlling the power switch component,said power controller component having a controller communicationinterface for communicating over the communication link to the powerswitch component.
 2. The system of claim 1 wherein the power controllercomponent is configured as an integrated assembly within the powerswitch component.
 3. The system of claim 1 wherein the power controlcomponent is position as a separate unit from the power switch componentand communicates with the power switch component over at least one of adedicated control facility and the communication link.
 4. The system ofclaim 1, further comprising a field device associated with the powercontrol system, the field device being selected from the groupconsisting of an actuator, an accelerometer, a valve positioner, a gaugeincluding a pressure gauge, a solenoid, a power supply, a heater, avalve including a solenoid valve, a meter, a motor, a pump, a switchincluding a thermal switch, a fusible link, and a memory device.
 5. Apower control system having a plurality of components, the systemcomprising: a system control component for generating a switch controlsignal; a limit control component for receiving a sensed limit operatingcharacteristic and generating a limit control signal as a function ofthe sensed limit operating characteristic; a communication linkconfigured for providing a communication between two of the plurality ofpower control system components; and a power control unit including aplurality of power control components and a unit integration couplingmechanism for mechanical and electrical coupling of the components ofthe power control unit, the power control unit including: a power supplyinterface for receiving power from a power supply, a power loadinterface for providing, at least a portion of, the received supplypower to a power load, a power switch component for selectivelyproviding electrical energy to a load responsive to the switch controlsignal and adapted to the coupling mechanism, the power switch componentincluding a power switch communication interface configured tocommunicate with the communication link, and a limit component forcontrolling the delivery of the supply power to the power switchcomponent responsive to the limit control signal.
 6. The system of claim5 wherein a plurality of the power control components within the powercontrol unit generates one or more power control operatingcharacteristics.
 7. The system of claim 6 wherein the one or more powercontrol operating characteristics are selected from the group consistingof a resistance, a current, a voltage, a Hall effect voltage, an energy,a mass, a power including an electrical power, a capacitance, aninductance, a reluctance, a phase, a timing, a frequency, a time, amode, a status, a failure, a position, an alert, an alarm, a state, amagnetic intensity, data, and a parameter.
 8. The system of claim 5wherein a plurality of the power control components within the powercontrol unit generates a self-identification message over thecommunication link.
 9. The system of claim 5, further comprising anintra-component diagnostics module.
 10. The system of claim 5, furthercomprising an inter-component diagnostics module for diagnosing anoperating event of the power control system.
 11. The system of claim 5,further comprising a system diagnostic module including a systemdiagnostic parameter selected from the group consisting of a diagnostic,a calibration, a profile, a configuration, a system administration, asystem operation, an operating characteristic, an event, a status, afailure, a mode, and a state.
 12. The system of claim 5, furthercomprising a system diagnostic module including a diagnostic functionselected from the group consisting of an algorithm, a program, anartificial intelligence module, a modeling module, a mapping, agraphical analysis, a rule, a comparator, and a look-up table.
 13. Thesystem of claim 5, further comprising a system diagnostic moduleincluding a diagnostic function selected from the group consisting of aneural network, an empirical data, a numerical data, a fuzzy logiccircuit, a neural fuzzy circuit, a polynomial algorithm, a residual lifealgorithm, an artificial intelligence module, a modeling module, and astatistical function.
 14. The system of claim 5, further comprising anoperational monitoring system monitoring an occurrence associated withone or more operating events selected from the group consisting of achange of a state, a change of a mode, a change of a status, a failure,a change of a field parameter, a change of the field operatingcharacteristic, a value of a field parameter exceeding a threshold, analarm, an alert, and a value of the field operating characteristicexceeding a threshold.
 15. The system of claim 5 wherein the powercontrol unit further comprises a load sensor for sensing an operatingcharacteristic of the power load.
 16. The system of claim 5 wherein thepower control unit further comprises a power measurement component andsensor for sensing at least a voltage and a current.
 17. The system ofclaim 5 wherein the power switch component includes a switch deviceselected from the group consisting of a contactor, a relay, a solidstate device, a knife switch, a mercury switch, and a cam switch. 18.The system of claim 5 wherein the system includes a plurality of powercontrol units, each of which communicates with the system controlcomponent and between each other over the communication link.
 19. Thesystem of claim 5, further comprising a communication interface forcommunicating between a plurality of power control systems and with apower control management or administration system.
 20. The system ofclaim 5, further comprising an communication interface for communicatingwith an external system selected from the group consisting of a powercontrol management a fabrication system, a manufacturing system, anassembly system, a processing system, an operational control system, anasset management system, a maintenance system including a predictivemaintenance system, and a supervisory control and data acquisition(SCADA) system.
 21. The system of claim 5 wherein the integratedcoupling mechanism provides at least one of inter-component associationand inter-component alignment.
 22. The system of claim 5 wherein one ormore components of the power control unit includes a processing systemfor performing an system or unit operating process selected from thegroup consisting of a diagnostics, a trouble shooting method, a faultdetection, a fault isolation, a root cause, a setting, a limit, athreshold, a calibration, a failure prediction, a maintenance procedure,a validation, a verification, a traceability, an auto-configuration, anarchitecture alignment, a fingerprint, an identification, a theoreticalmodeling, a self-administration, and a self-tuning rule.
 23. The systemof claim 5 wherein the power control unit includes a function selectedfrom the group consisting of a thermal protection, status indication,and zero cross detection.
 24. A power control system having a pluralityof components, the control system comprising: a first control componenthaving a plurality of first component versions; a second controlcomponent having a plurality of second component versions; and a systemintegration coupling mechanism for mechanical, electrical, andcommunication coupling the first component and the second component,wherein each of the first component versions being operable with each ofthe second component versions when coupled with the system integrationcoupling mechanism.
 25. The system of claim 24 wherein the firstcomponent and the second component each include a proximity recognitionmodule.
 26. The system of claim 24 wherein the first component generatesa self-identification and the second component receives the firstself-identification message.
 27. The system of claim 24 wherein thesecond component includes a configuration management module, the secondcomponent initiating a self-configuration mode responsive to thereceived first self-identification message.
 28. The system of claim 24wherein the second component includes a system profile and compares thereceived first self-identification message to the system profile, thesecond component initiating an action in response to the comparison. 29.The system of claim 24 wherein the first component and the secondcomponent each includes a processing module and a memory.
 30. The systemof claim 24 wherein the system integration coupling mechanism providesfor mechanical alignment of the first component and the secondcomponent.
 31. A power control system including a plurality of controlsystem components, the control system comprising: a system integrationcoupling mechanism for mechanical, electrical, and communicationcoupling of a plurality of components into the power control system; aplurality of self-identifying components; and a plurality ofself-configuring components, the self-configuring being responsive to areceived self-identification of another one of the plurality ofcomponents.
 32. The system of claim 31 wherein two or more of theplurality of components includes a memory for storing a firstconfiguration and a second configuration, the first configuration beingassociated with a first component and the second configuration beingassociated with a second component.
 33. The system of claim 31 wherein asecond component receives a second component configuration from a firstcomponent in response to installation of the second component in thepower control system/the
 34. The system of claim 31 wherein the firstcomponent further includes a third configuration, the thirdconfiguration being indicative of at least on of a prior configuration,a predetermined configuration, and a default configuration.
 35. A methodof controlling power in a power control system having a plurality ofpower control component, the method comprising: generatingself-identification of each component within a power control system;comparing the identity of each component as self-identified to a atleast one of a predetermined configuration and a profile; andreconfiguring a characteristic of one or more components responsive tothe comparing.
 36. A power control system comprising: a base including ahousing configured for releasably receiving a control unit and a cavitywithin the housing for receiving a power switch, the base including aninput power terminal for coupling to an input power source, an outputpower terminal for coupling to a power receiving load, and couplingfixtures for fixedly and electrically coupling to input and output powerterminals and control terminals of the received power switch; and acontrol unit configured to control the power switch for selectivelyproviding, at least a portion of, the power received at the input powerterminal to the output power terminal, the control unit having a housingadapted to be releasably coupled to the base housing, the control unitand base each are each configured to electrically couple the controlunit to the control terminals of the received power switch as a functionof the control unit being coupled to the base.
 37. A power controlsystem comprising: a base including a housing for releasably receiving acontrol unit and defining a first cavity for receiving a power switch, asecond cavity for receiving a limit switch, an input power terminal, anoutput power terminal coupled to receive switched power from an outputterminal a received power switch, control couplers for coupling to aninput and an output control terminal of the received power switch, and aplurality of electrical connections; a limit switch within the secondcavity and coupled by a portion of the electrical connections in serieswith the input power terminal, an input terminal of the received powerswitch received within the first cavity, and the output power terminal;a control unit for providing control signals to the limit switch andcontrol signals to the received power switch for selectively providing,at least a portion of, the power received at the input power terminal tothe output power terminal, the control unit having a housing adapted tobe releasably coupled to the base housing, the control unit and base areeach configured to electrically couple the control unit to the controlterminals of the received power switch as a function of the control unitbeing releasably coupled to the base, the control unit including a limitcomponent having a threshold limit function, the limit switch controlsignals being a function of the threshold limit function.
 38. A controlassembly for use in an integrated power control system having a baseincluding a housing and defining a cavity within the housing forreceiving a power switch, the control assembly comprising: a controlmodule configured for generating control signals for controlling thepower switch for selectively providing power to a load; and a controlhousing for housing the control module and adapted to be releasablycoupled to the base housing, the control housing being configured forelectrically coupling to control couplers on the base housing forproviding the generated control signals to the power switch within thehousing cavity upon coupling the control housing to the base housing.39. A method of assembling a power control unit, the method comprising:inserting a power switch into a cavity defined by a base having housing;coupling an input power terminal to an input terminal of the powerswitch; coupling an output power terminal to an output terminal of thepower switch; coupling a first control attachment fixture to a firstcontrol terminal of the power switch; coupling a second controlattachment fixture to a second control terminal of the power switch; andinserting a control unit having a control housing onto the base housing,the control housing and the base housing being configured for releasablycoupling the inserted control unit to the base, the inserting a controlunit including compressively coupling the control unit to the firstcontrol attachment fixture and the second control attachment fixture andcompleting an electrical connection between the control unit and each ofthe control terminals of the power switch.